Fitter content - 4th sem-PracticalModule 1: Drill jig 4.1.159 Make a simple drilling jig 1 4.1.160...

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NATIONAL INSTRUCTIONALMEDIA INSTITUTE, CHENNAI

FITTER

SECTOR: Production & Manufacturing

TRADE PRACTICAL

Post Box No. 3142, CTI Campus, Guindy, Chennai - 600 032

2nd Year (Volume II of II)

NSQF LEVEL - 5

DIRECTORATE GENERAL OF TRAININGMINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP

GOVERNMENT OF INDIA

Copyright Free Under CC BY Licence

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Sector : Production & ManufacturingDuration : 2 - YearsTrade : Fitter 2nd Year (Volume II of II) - Trade Practical - NSQF level 5

First EditionFirst Reprint : January, 2019 Copies : 5,000

: October, 2018 Copies : 1,000

Rs.170/-

All rights reserved.

No part of this publication can be reproduced or transmitted in any form or by any means, electronic or mechanical, includingphotocopy, recording or any information storage and retrieval system, without permission in writing from the NationalInstructional Media Institute, Chennai.

Published by:

NATIONAL INSTRUCTIONAL MEDIA INSTITUTEP. B. No.3142, CTI Campus, Guindy Industrial Estate,

Guindy, Chennai - 600 032.Phone : 044 - 2250 0248, 2250 0657, 2250 2421

Fax : 91 - 44 - 2250 0791email : [email protected], [email protected]

Website: www.nimi.gov.in


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FOREWORD

The Government of India has set an ambitious target of imparting skills to 30 crores people, one out of every four Indians, by 2020 to help them secure jobs as part of the National Skills Development Policy. Industrial Training Institutes (ITIs) play a vital role in this process especially in terms of providing skilled manpower. Keeping this in mind, and for providing the current industry relevant skill training to Trainees, ITI syllabus has been recently updated with the help of Mentor Councils comprising various stakeholder's viz. Industries, Entrepreneurs, Academicians and representatives from ITIs.

The National Instructional Media Institute (NIMI), Chennai has now come up with instructional material to suit the revised curriculum for Fitter 2nd Year (Volume II of II) Trade Practical NSQF Level - 5 in Production & Manufacturing Sector under Semester Pattern. The NSQF Level - 5 Trade Practical will help the trainees to get an international equivalency standard where their skill proficiency and competency will be duly recognized across the globe and this will also increase the scope of recognition of prior learning. NSQF Level - 5 trainees will also get the opportunities to promote life long learning and skill development. I have no doubt that with NSQF Level - 5 the trainers and trainees of ITIs, and all stakeholders will derive maximum benefits from these IMPs and that NIMI's effort will go a long way in improving the quality of Vocational training in the country.

The Executive Director & Staff of NIMI and members of Media Development Committee deserve appreciation for their contribution in bringing out this publication.

Jai Hind

RAJESH AGGARWALDirector General/ Addl. Secretary

Ministry of Skill Development & Entrepreneurship,Government of India.

New Delhi - 110 001


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PREFACE

The National Instructional Media Institute (NIMI) was established in 1986 at Chennai by then DirectorateGeneral of Employment and Training (D.G.E & T), Ministry of Labour and Employment, (now under DirectorateGeneral of Training, Ministry of Skill Development and Entrepreneurship) Government of India, with technicalassistance from the Govt. of the Federal Republic of Germany. The prime objective of this institute is todevelop and provide instructional materials for various trades as per the prescribed syllabi under the Craftsmanand Apprenticeship Training Schemes.

The instructional materials are created keeping in mind, the main objective of Vocational Training underNCVT/NAC in India, which is to help an individual to master skills to do a job. The instructional materials aregenerated in the form of Instructional Media Packages (IMPs). An IMP consists of Theory book, Practicalbook, Test and Assignment book, Instructor Guide, Audio Visual Aid (Wall charts and Transparencies) andother support materials.

The trade practical book consists of series of exercises to be completed by the trainees in the workshop.These exercises are designed to ensure that all the skills in the prescribed syllabus are covered. The tradetheory book provides related theoretical knowledge required to enable the trainee to do a job. The test andassignments will enable the instructor to give assignments for the evaluation of the performance of a trainee.The wall charts and transparencies are unique, as they not only help the instructor to effectively present atopic but also help him to assess the trainee's understanding. The instructor guide enables the instructor toplan his schedule of instruction, plan the raw material requirements, day to day lessons and demonstrations.

IMPs also deals with the complex skills required to be developed for effective team work. Necessary carehas also been taken to include important skill areas of allied trades as prescribed in the syllabus.

The availability of a complete Instructional Media Package in an institute helps both the trainer andmanagement to impart effective training.

The IMPs are the outcome of collective efforts of the staff members of NIMI and the members of the MediaDevelopment Committees specially drawn from Public and Private sector industries, various training institutesunder the Directorate General of Training (DGT), Government and Private ITIs.

NIMI would like to take this opportunity to convey sincere thanks to the Directors of Employment & Trainingof various State Governments, Training Departments of Industries both in the Public and Private sectors,Officers of DGT and DGT field institutes, proof readers, individual media developers and coordinators, but forwhose active support NIMI would not have been able to bring out this materials.

R. P. DHINGRAROTCERID EVITUCEXE 230 006 - iannehC


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ACKNOWLEDGEMENT

National Instructional Media Institute (NIMI) sincerely acknowledges with thanks for the co-operation and

contribution extended by the following Media Developers and their sponsoring organisations to bring out this

Instructional Material (Trade Practical) for the trade of Fitter under Production & Manufacturing Sector for ITIs.

MEDIA DEVELOPMENT COMMITTEE MEMBERS

Shri. T. Janakiram _ Assistant Director (Retd.),Govt RIC, North Chennai - 21

Shri. M. Sampath _ Training officer (Retd.)CTI, Chennai-32.

Shri. M. Sangarapandian _ Training officer (Retd.)CTI, Chennai - 32

Shri. K. Kesavan _ Asst. App. Advisor Junior (Retd)DET, Tamilnadu

Shri. C.C. Subramanian _ Training officer (Retd.)Balamandir PHM ITI, Chennai - 17

Shri. K. Srinivasa Rao _ Joint Director,Co-ordinator, NIMI, Chennai - 32

Shri. G. Michael Johny _ Assistant Manager,Co-ordinator, NIMI, Chennai - 32

NIMI records its appreciation for the Data Entry, CAD, DTP operators for their excellent and devoted services inthe process of development of this Instructional Material.

NIMI also acknowledges with thanks the invaluable efforts rendered by all other NIMI staff who have contributedtowards the development of this Instructional Material.

NIMI is also grateful to everyone who has directly or indirectly helped in developing this Instructional Material.


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INTRODUCTION

TRADE PRACTICAL

The trade practical manual is intented to be used in practical workshop . It consists of a series of practicalexercises to be completed by the trainees during the Fourth Semester Course of the Fitter Trade supplementedand supported by instructions/ informations to assist in performing the exercises. These exercises aredesigned to ensure that all the skills in compliance with NSQF LEVEL - 5 syllabus are covered.

The manual is divided into six modules. The distribution of time for the practical in the six modules are givenbelow.

Module 1 Drill jig 25 Hrs

Module 2 Repairing technique 200 Hrs

Module 3 Hydraulics and pneumatics 100 Hrs

Module 4 Preventive maintenance 75 Hrs

Module 5 Erection and testing 75 Hrs

Module 6 Project work/ In plant training 50 Hrs

Total 525 Hrs

The skill training in the shop floor is planned through a series of practical exercises centred around somepractical project. However, there are few instances where the individual exercise does not form a part of project.

While developing the practical manual a sincere effort was made to prepare each exercise which will be easyto understand and carry out even by below average trainee. However the development team accept that thereis a scope for further improvement. NIMI looks forward to the suggestions from the experienced training facultyfor improving the manual.

TRADE THEORY

The manual of trade theory consists of theoretical information for the Fourth Semester Course of the Fitter Trade.The contents are sequenced according to the practical exercise contained in NSQF LEVEL - 5 syallabus onTrade practical. Attempt has been made to relate the theoretical aspects with the skill covered in each exerciseto the extent possible. This correlation is maintained to help the trainees to develop the perceptional capabilitiesfor performing the skills.

The Trade Theory has to be taught and learnt along with the corresponding exercise contained in the manualon trade practical. The indications about the corresponding practical exercises are given in every sheet of thismanual.

It will be preferable to teach/learn the trade theory connected to each exercise atleast one class beforeperforming the related skills in the shop floor. The trade theory is to be treated as an integrated part of eachexercise.

The material is not for the purpose of self learning and should be considered as supplementary to class roominstruction.


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Exercise No. Title of the Exercise Page No.

Module 1: Drill jig

4.1.159 Make a simple drilling jig 1

4.1.160 Use simple jigs and fixtures for drilling 6

Module 2: Repairing technique

4.2.161 Marking out for angular outlines, filing and fitting the inserts into gaps 8

4.2.162 Exercises on finished material, such as aluminium/ brass/ copper/ stainlesssteel, marking out, cutting to size, drilling, tapping etc. without damage tosurface of finished articles 11

4.2..163 Making an adjustable spanner: Marking out as per Blue print drilling, cutting,straight and curve filing, threading, cutting slot and cutting internal threadswith taps 13

4.2.164 Dismantling and mounting of pulleys 18

4.2.165 Making and replacing damaged keys 21

4.2.166 Dismounting, repairing damaged gears and mounting and check forworkability 23

4.2.167 Repair & replacement of belts and check for workability 27

4.2.168 Making of template / gauge to check involute profile 30

4.2.169 Repair of broken gear tooth by stud and repair broken gear teeth by dovetail 32

4.2.170 Make hexagonal slide fitting 35

4.2.171 Prepare different types of documentation as per industrial need by differentmethods of recording information 38

4.2.172 Marking out on the round sections for geometrical shaped fittings such asspline with 3 or 4 teeth. Finishing and fitting to size, checking up the facesfor universality 52

Module 3: Hydraulics and pneumatics

4.3.173 Identify pneumatic components - Compressor, Pressure gauge, Filter -Regulator- Lubricator (FRL) unit - Different types of valves and actuators 56

4.3.174 Dismantle, replace and assemble FRL unit 58

4.3.175 Demonstrate knowledge of safety procedures in pneumatic systems andpersonal protective equipment (PPE) 60

4.3.176 Identify the parts of a pneumatic cylinder 62

4.3.177 Dismantle and assemble a pneumatic cyclinder 64

4.3.178 Construct a circuit for the direction & speed control of a small bore singleacting (s/a) pneumatic cylinder 67

4.3.179 Construct a control circuit for the control of a d/a pneumatic cylinder withmomentry input signals 70

4.3.180 Construct a circuit for the direct & indirect control of a d/a pneumatic cylinderwith a single & double solenoid valve 72

4.3.181 Dismantling and assembling of solenoid valves 78

CONTENTS


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Exercise No. Title of the Exercise Page No.

4.3.182 Demonstrate knowledge of safety procedures in hydraulic systems(demo by video) 81

4.3.183 Identify hydraulic components - Pumps, Reservoir, Fluids, Pressure relief valve(PRV), Filters, different types of valves, actuators and hoses 82

4.3.184 Inspect fluid levels, service reservoirs clean/ replace filters 84

4.3.185 Inspect hose for twist, kinks and minimum bend radius. Inspect hose/ tubefittings 89

4.3.186 Identify internal parts of hydraulic cylinders, pumps/ motors 91

4.3.187 Construct a circuit for the control of a s/a hydraulic cylinder using a 3/2 wayvalve (Weight loaded d/a cylinder may be used as a s/a cylinder), 4/2 and 4/3way valves 97

4.3.188 Maintenance, trouble shooting and safety aspects of pneumatic and hydraulicsystems (The practical for this component may demonstrated by video) 99

Module 4: Preventive maintenance

4.4.189 Dismantle, overhauling and assemble cross slide & hand slide of lathecarriage 100

4.4.190 Simple repair of machinery: Making of packing gaskets 102

4.4.191 Check washers, gasket, clutch, keys, jibs, cotter, Circlip etc and replace/repair if needed 105

4.4.192 Use hollow punches, extractor, drifts, various types of hammers and spannersetc for repair work 114

4.4.193 Dismantling, assembling of different types of bearing and check forfunctionality 117

4.4.194 Perform routine check of machine and do replenish as per requirement 124

4.4.195 Inspect of machine tools such as alignment, levelling 126

4.4.196 Accuracy testing of machine tools such as geometrical parameters 130

Module 5: Erection and testing

4.5.197 Practicing, making various knots, correct loading of slings, correct and saferemoval of parts 135

4.5.198 Erect simple machines 140

Module 6: Project work/ In plant training


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LEARNING / ASSESSABLE OUTCOME

On completion of this book you shall be able to

• Make drill jig & produce components on drilling machine by usingjigs and check for correctness.

• Plan, dismantle, repair and assemble different damagedmechanical components used for power transmission & checkfunctionality of mechanical components like Pulley, Gear, Keys,Jibs and Shafts.

• Identify, dismantle, replace and assemble different pneumaticsand hydraulics components like Compressor, Pressure Gauge,Filter Regulator Lubricator, Valves and Actuators.

• Construct circuit of pneumatics and hydraulics observingstandard operating procedure & safety aspect.

• Plan & perform basic day to day preventive maintenance,repairing and check functionality of Drill Machine, Power Saw andLathe.

• Plan, erect simple machine and test machine tool accuracy of DrillMachine, Power Saw and Lathe.


SYLLABUS2nd Year (Volume II of II) Duration: Six Months

Professional KnowledgeWeekNo.

Ref. LearningOutcome

Professional Skills with Indicative hrs.

Make drill j ig &produce componentson drill machine byusing jigs and checkfor correctness.

79 159. Make a simple drilling jig. (20hrs.)

160. Use simple jigs and fixtures fordrilling. (5 hrs.)

Drilling jig-constructional features,types and uses. Fixtures-Constructional features, types anduses.

80 Plan, dismantle, repairand assemble differentdamaged mechanicalcomponents used forpower transmission &check functionality.[Different DamageM e c h a n i c a lComponents – Pulley,Gear, Keys, Jibs andShafts.]

161. Marking out for angular outlines,filing and fitting the inserts intogaps. (10 hrs.)

162. Exercises on finished materialsuch as aluminium/ brass/ copper/ stainless steel, marking out,cutting to size, drilling, tappingetc. without damage to surface offinished articles. (15 hrs.)

Aluminium and its alloys. Uses,advantages and disadvantages,weight and strength as comparedwith steel. Non-ferrous metals suchas brass, phosphor bronze,gunmetal, copper, aluminium etc.Their composition and purposes,where and why used, advantagesfor specific purposes, surfacewearing properties of bronze andbrass.

81-do- 163. Making an adjustable spanner: -

Marking out as per Blue print,drilling, cutting, straight and curvefiling, threading, cutting slot andcutting internal threads with taps.(25 hrs.)

Installation, maintenance andoverhaul of machinery andengineering equipment. Powertransmission elements. Theobject of belts, their sizes andspecifications, materials of whichthe belts are made, selection ofthe type of belts with theconsideration of weather, load andtension methods of joining leatherbelts

82-84 -do- 164. Dismantling and mounting ofpulleys. (10 hrs.) 165. Making &replacing damaged keys. (15 hrs.)166. Dismounting, repairingdamaged gears and mounting andcheck for workability. (15 hrs.)167. Repair & replacement of beltsand check for workability. (10 hrs.)

Vee belts and their advantagesand disadvantages, Use ofcommercial belts, dressing andresin creep and slipping,calculation. Powertransmissions- couplingtypesflange coupling,-Hookscouplinguniversal coupling andtheir different uses. Pulleys-types-solid, split and „V? beltpulleys, standard calculation fordetermining size crowning offaces-loose and fast pulleys-jockey pulley. Types of drives-open and cross belt drives. Thegeometrical explanation of thebelt drivers at an angle.

168. Making of template/gauge tocheck involute profile. (25 hrs.)

85-do-

Power transmission –by gears,most common form spur gear, setnames of some essential partsof the set-The pitch circles,Diametral pitch, velocity ratio ofa gear set.


86 -do-169. Repair of broken gear tooth

by stud and repair brokergear teeth by dovetail. (25hrs.)

Helical gear, herring bone gears,bevel gearing, spiral bevel gearing,hypoid gearing, pinion and rack,worm gearing, velocity ratio ofworm gearing. Repair of gear teethby building up and dovetailmethod.

87 -do-170. Make hexagonal slide fitting.

(20 hrs.)171. Prepare different types of

documentation as perindustrial need by differentmethods of recordinginformation. (5 hrs.)

Importance of Technical Englishterms used in industry –(in simpledefinition only)Technical forms,process charts, activity logs, inrequired formats of industry,estimation,cycle time,productivity reports, job cards.

88 -do-172. Marking out on the round sections

for geometrical shaped fittingssuch as spline with 3 or 4 teeth.Finishing and fitting to size,checking up the faces foruniversality. (25 hrs.)

Fluid power, Pneumatics,Hydraulics, and theircomparison, Overview of apneumatic system, Boyle’slaw. Overview of an industrialhydraulic system, Applications,Pascal’s Law.

89 Identify, dismantle,replace andassemble differentpneumatics andh y d r a u l i c sc o m p o n e n t s .[ D i f f e r e n tcomponents –C o m p r e s s o r ,Pressure Gauge,Filter RegulatorLubricator, Valvesand Actuators.

173. Identify pneumatic components –Compressor, pressure gauge,Filter-Regulator-Lubricator (FRL)unit, and Different types of valvesand actuators. (2 hrs.)

174. Dismantle, replace, and assembleFRL unit(5 hrs.)

175. Demonstrate knowledge of safetyprocedures in pneumatic systemsand personal Protective Equipment(PPE)(2 hrs.)

176. Identify the parts of a pneumaticcylinder (1 hrs.)

177.Dismantle and assemble apneumatic cylinder (8 hrs.)

178. Construct a circuit for the direction& speed control of a small-boresingle-acting (s/a) pneumaticcylinder(7 hrs.)

Compressed air generation andconditioning, Air compressors,Pressure regulation, Dryers, Airreceiver, Conductors and fittings,FRL unit, Applications ofpneumatics, Hazards & safetyprecautions in pneumaticsystems.

Pneumatic actuators:- Types,Basic operation, Force, Strokelength, Singleacting and double-acting cylinders.

90 Construct circuit ofpneumatics andhydraulics observingstandard operatingprocedure& safetyaspect.

179. Construct a control circuit for thecontrol of a d/a pneumaticcylinder with momentary inputsignals(5 hrs.)

180. Construct a circuit for the direct& indirect control of a d/apneumatic cylinder with a single& double solenoid valve(10 hrs.)

181. Dismantling &Assembling ofsolenoid valves(10 hrs.)

Pneumatic valves:- Classification,Symbols of pneumaticcomponents, 3/2way valves (NO &NC types) (manually actuated &pneumatically-actuated) & 5/2-wayvalves, Check valves, Flow controlvalves, Oneway flow control valvePneumatic valves: Roller valve,Shuttle valve, Two-pressure valveElectro-pneumatics: Introduction,3/2way single solenoid valve, 5/2-way single solenoid valve, 5/2-waydouble solenoid valve, Controlcomponents Pushbuttons (NO &NC type) and Electromagneticrelay unit, Logic controls


91 Identify, dismantle,replace and assembledifferent pneumaticsand hydraulicscomponents. [Differentcomponents –Compressor, PressureGauge, Filter RegulatorLubricator, Valves andActuators.]

182. Demonstrate knowledge of safetyprocedures in hydraulic systems(Demo by video) (5 hrs.)

183. Identify hydraulic components –Pumps, Reservoir, Fluids,Pressure relief valve (PRV), Filters,different types of valves, actuators,and hoses (5 hrs.)

184 Inspect fluid levels, servicereservoirs, clean/replace filters(5hrs.)

185.Inspect hose for twist, kinks, andminimum bend radius, Inspecthose/tube fittings(5 hrs.)

186. Identify internal parts of hydrauliccylinders, pumps/motors(5 hrs.)

- Symbols of hydrauliccomponents,Hydraulic oils –function,properties, and types,Contamination in oils and itscontrol

- Hydraulic Filters – types,constructional features, andtheir typical installationlocations, cavitation, Hazards& safety precautions inhydraulic systems

- Hydraulic reservoir &accessories, Pumps,Classification – Gear/vane/piston types, Pressure reliefvalves – Direct acting andpilot-operated types

- Pipes, tubing, Hoses andfittings – Constructionaldetails, Minimum bend radius,routing tips for hoses

92 Construct circuit ofpneumatics andh y d r a u l i c sobserving standardo p e r a t i n gprocedure& safetyaspect.

187. Construct a circuit for the controlof a s/a hydraulic cylinder using a3/2-way valve (Weight loaded d/acylinder may be used as a s/acylinder), 4/2 & 4/3 way valves. (10hrs.)

188. Maintenance, troubleshooting, andsafety aspects of pneumatic andhydraulic systems (The practicalfor this component maydemonstrated by video) (15 hrs.)

- Hydraulic cylinders –Types- Hydraulic motors –Types- Hydraulic valves: Classification,

Directional Control valves – 2/2-and 3/2-way valves

- Hydraulic valves: 4/2- and 4/3-way valves, Centre positions of 4/3-way valves

- Hydraulic valves: Check valvesand Pilot-operated check valves,Load holding function

- Flow control valves: Types, Speedcontrol methods – meter-in andmeterout

- Preventive maintenance &troubleshooting of pneumatic &hydraulic systems, Systemmalfunctions due tocontamination, leakage, friction,improper mountings, cavitation,and proper sampling of hydraulicoils

93 Method or fixing geared wheelsfor various purpose drives.General cause of the wear andtear of the toothed wheels andtheir remedies, method of fittingspiral gears, helical gears, bevelgears, worm and worm wheelsin relation to required drive. Careand maintenance of gears.

Plan & perform basicday to day preventivemaintenance, repairingand checkfunctionality.[SimpleMachines – DrillMachine, Power Sawand Lathe]

189. Dismantle, overhauling &assemble cross-slide &handslide of lathe carriage.(25 hrs.)


94-96 -do-

Method of lubrication-gravity feed,force (pressure) feed, splashlubrication. Cutting lubricants andcoolants: Soluble off soaps, suds-paraffin, soda water, commonlubricating oils and their commercialnames, selection of lubricants.Clutch: Type, positive clutch(straight tooth type, angular toothtype) . Washers-Types andcalculation of washer sizes. Themaking of joints and fitting packing.Chains, wire ropes and clutches forpower transmission. Their types andbrief description.

190. Simple repair of machinery: -Making of packing gaskets.(5 hrs.)

191. Check washers, gasket, clutch,keys, jibs, cotter, Circlip, etc. andreplace/repair if needed. (5 hrs.)

192. Use hollow punches, extractor,drifts, various types of hammersand spanners, etc. for repairwork. (15 hrs.)

193. Dismantling, assembling ofdifferent types of bearing andcheck for functionality. (15 hrs.)

194. Perform routine check ofmachine and do replenish as perrequirement. (10 hrs.)

97Plan, erect simplemachine and testmachine toolaccuracy. [SimpleMachines – DrillMachine, PowerSaw and Lathe]

195. Inspection of Machine tools suchas alignment, levelling. (10 hrs.)

196. Accuracy testing of Machinetools such as geometricalparameters. (15 hrs.)

Lubrication and lubricants-purpose of using different types,description and uses of each type.Method of lubrication. A goodlubricant, viscosity of the lubricant,Main property of lubricant. How afilm of oil is formed in journalBearings.

98-99 -do-197. Practicing, making various knots,

correct loading of slings, correctand safe removal of parts. (5 hrs.)

198. Erect simple machines. (45 hrs.)

Foundation bolt: types (rag, Lewiscotter bolt) description of eacherection tools, pulley block, crowbar, spirit level, Plumb bob, wirerope, manila rope, wooden block.The use of lifting appliances,extractor presses and their use.Practical method of obtainingmechanical advantage. The slingsand handling of heavy machinery,special precautions in the removaland replacement of heavy parts.

In-plant training/ Project work1. Pulley Extractor2. Cam Vice3. Link Mechanism4. Adjustable Fixture5. Slider Crank6. Hand Lever Punch7. Setup hydraulic and pneumatic circuit and test the functioning of piston

movement.

100-101

102-103

104

Revision

Examination


1

Production & Manufacturing Exercise 4.1.159Fitter - Drill jig

Make a simple drilling jigObjectives: At the end of this exercise you shall be able to• machine the parts of a drill jig and maintain the same for size• assemble the parts of a drill jig as per assembly drawing• check the dimensions and locations.


2 Production & Manufacturing: Fitter (NSQF Level - 5): Exercise 4.1.159


3Production & Manufacturing: Fitter (NSQF Level - 5): Exercise 4.1.159


4

Job sequence

TASK 1: Making top plate

• Check the raw material.

• File and finish the job 52 X 110 X 14mm as per drawing.

• Mark the hole centres.

• Set the job on drilling machine.

• Drill the holes ∅ 5.8mm for reaming.

• Ream the hole using 6mm reamer.

• Drill 2 holes of ∅ 8.5mm for inserting hook bolt.

• Drill 4 nos of ∅ 11.8mm for fixing bush.

• Ream the ∅ 11.8mm hole using 12mm reamer to getH7 finish.

• Remove burr in the sharp corner.

TASK 3: Making jig bush

• Chamfer the end of dia 12mm.

• Part to a length of 21mm.

• Repeat the same for 4 pieces.

• Hold the dia 12mm and face the other side to a lengthof 20mm.

• Chamfer as per drawing.

• Remove the burrs.

Production & Manufacturing: Fitter (NSQF Level - 5): Exercise 4.1.159

TASK 2: Making knob


• Hold the job in 3 jaw chuck.

• Make centre drill and enlarge the hole to ∅ 7mm ± 0.1.

• Turn dia to a length of 20mm.

• Turn step dia to length of 10mm.

• Knurl as per drawing.

• Reverse the job hold the knurled portion with softpackings.

• Face to a length of 16 mm.

• Chamfer as per drawing.

• Remove the job from lathe, hold on bench vice andmake the thread of M8 using tap.

• Remove the burrs.

• Repeat the above for other knob.


• Hold the job in three jaw chuck.

• Face, centre drill and enlarge the hole to dia 5.8mm.

• Ream the hole ∅ 6mm.

• Turn dia 18mm to required length.

• Turn step of dia 12mm to a length of 15mm.


5

TASK 4: Making hook bolt


• Bend the rod as per drawing using anvil and hammer.

• File flat surface as per section ‘AA’.

• Chamfer the length side for threading.


• Make thread using 8mm hand die with stock.

• Check the thread using ∅ 8mm nut

• Finish as per drawing.

Drill jig assembly

• Clean all the parts.

• Deburr sharp corners if any.

• Fit the bush (Task 3) in the top plate (Task 2).

• Fix the ∅ 6mm X 16mm dowel pin on the top plate.

• Fix the hook bolt 2 nos.

• Screw the knob in hook bolt.

• Insert the channel to be drilled.

• Now the drill jig is ready for drilling.


6

Production & Manufacturing Exercise 4.1.160Fitter - Drill jig

Use simple jigs and fixtures for drillingObjectives: At the end of this exercise you shall be able to• locate the work piece in a jig• drill the hole on MS Channel• check for the accuracy.


7

Job sequencePlate jig - trial

• Use previous Ex.No. 4.1.159 drill jig.

• Remove the top plate from the plate jig.

• Locate component between the hook bolt and touchwith stopper pin.

• Clamp the top plate with the knobs.

• Drill dia 6 x 4 Nos.

• Remove the top plate.

• Take out the component from the jig.

• Check the component with a vernier caliper.



8

Production & Manufacturing Exercise 4.2.161Fitter - Repairing Technique

Marking out for angular outlines, filing and fitting the inserts into gapsObjectives: At the end of this exercise you shall be able to• mark an angular out lines on part A & B with an accuracy of ± 0.02mm• file part A & B maintain the accuracy of H7/g6 for fitting• fit inserts.



Job sequence

• Cut the raw materials as per the dimensions

• File right angle and mark off part A & B with vernierheight gauge and vernier bevel protractor

• Punch on the marked lines / out lines

• Remove unwanted materials by hacksawing and chaindrilling

• File Part A&B with a linear accuracy of ± 0.02mm andangular of ± 5’

• Checking the angular dimensions by vernier bevelprotractor

• Fit Part : A & B and finish

Safety

• Do not mark angular dimensions / angle by scale /set square while marking

• Do not use hammer for fitting


11


Exercises on finished material, such as aluminium/ brass/ copper/ stainlesssteel, marking out, cutting to size, drilling, tapping etc. without damage tosurface of finished articlesObjectives: At the end of this exercise you shall be able to• mark on the Aluminium, Brass, Copper with vernier height gauge• cut extra metal using hacksaw• drill counter sink, counter bore and ream• tap, finish and deburr.

A - Counter Bore - ∅ 6

B - Drilling - ∅12

C - Counter Sunk - ∅10

D - Ream - ∅ 6

E - Tap - M10

F - Tap - M8

G - Tap - M6

H - Counter Sunk - ∅12.5


12

Job sequence

• Check raw material

• File two adjacent side and on flat surface.

• Mark the size of 74 X 48 outer line.

• Punch identification mark.

• Remove the excess material using hacksaw.


• Mark the centre as per dimension

• Set the job on drilling machine

• Make drill holes as per standard chart

• Make Reaming, Counter boreing and tapping

• Make counter sinking as per dimensions.


13


Making an adjustable spanner: Marking out as per Blue print, drilling, cut-ting, straight and curve filing, threading, cutting slot and cutting internalthreads with tapsObjectives: At the end of this exercise you shall be able to• prepare different parts referring to the drawing• prepare for assembly• assemble all the parts• check for the accuracy.


17

Job sequence

TASK 1:

Part ‘A’ - Fixed jaw

• Check the raw material for the given size

• File the surface and side for straightness

• File the adjacent side for right angle

• Do the marking as per drawing with vernier height gauge

• Remove the excess material by hacksawing or chaindrilling

• Drill ∅10 hole for the R5 concave

• File and check for the dimension as per drawing

• Check the radius with radius gauge R5 & R3

• Drill the hole ∅ 3.8 mm from the side to the depth of 12mmand ream ∅ 4

• Drill ∅ 2 as per the drawing dimension

• De - burr and finish smooth surface

TASK 2:

Part 'B' - sliding jaw

• Check the raw material for the given size

• File the surface and side for straightness

• File the adjacent side for right angle

• Mark the job as per the drawing with vernier heightgauge

• Remove the excess material by hacksawing or chaindrilling and ∅4, 2 hole

• File the job for the dimension and check the dimension

• File for the radius edges

• File the edges and deburr the job

TASK 3:

Part - ‘C’ - Special screw

• Check the rod for ∅6 x 58 mm

• Turn the rod holding in 3 jaw chuck for ∅4mm, 10mmlength with h6 finish

• Do the threading M6 for the entire length

• Check with the die nut for threaded portion

Fixed jaw assembly

• Insert the rod into the fixed jaw and position it.

• Drill ∅2mm hole along with the fixed jaw


• Fit the cylindrical pin ∅2,

• Check the dimensions

TASK 4:

Part 'E' Knurled Nut

• Check the raw material as per the drawing size

• Hold the rod in the three jaw chuck and true

• Turn the round for ∅12mm

• Knurled the outer surface with knurling tool upto 15mmlength

• Drill ∅5 mm and tap the drilled hole by M6 Tap

• Chamfer the side 2 x 45°

• Do the parting off and chamfer the other side.

Part D: Sliding plate

• Check the metal sheet for the dimension

• File the sheet metal for straightness and right angle bydraw filing

• Mark the layout as per drawing and punch

• Bend the sheet metal with the help of 6mm flat byhammering

• Check for the dimension after bending

• Drill the ∅ 4 hole for the slot opening

• Chain drilling for the slot opening remove excess metal

• File the slot for the dimensions

• Drill ∅4mm in the position as per drawing

• File for 60° angle and check with bevel protractor

• Do the radius filing and remove the burr’s

Spanner assembly

• Check material size for all the parts

• File, mark and finish parts A & B to size

• Bend Part 'D' as per drawing

• Remove excess metal and finish to size

• File and finish square slot

• Drill and counter sink holes

• Turn, drill, tap, knurl and part off part E to size

• Step turn, cut external thread using and part off part'C' to size

• Assemble part C & A

• Rivet and join part B and D

• Assemble all the parts together


18


Dismantling and mounting of pulleysObjectives: At the end of this exercise you shall be able to• extract pulley using puller• extract pulley using arbor press• mount pulley on shaft.


19

Job sequenceExtract pulley from shaft

• Remove pulley using puller.

• Remove pulley using arbour press.

Extract pulley using puller

• Select correct size of puller, depending upon the sizeof the shaft and pulley.

• Clean end of the shaft using flat file, to remove any burrsor bulging on the end of the shaft.

• Place the legs of the puller diagonally opposite sides ofthe pulley to hold the pulley firmly (Fig 1).

• Position the centre screw of the puller by hand screwing,so that, sufficient centre screw length is available forcomplete removal of the pulley from the shaft.

• Apply few drops of oil, around the shaft before removing.

• Tighten the centre screw gradually using correct sizespanner and check whether the pulley is coming outfreely from the shaft, if not slightly hammer on the headof the centre screw, this will cause the pulley to comeout from the shaft freely.(Fig.2)

Extract pulley using Arbor press

• Clean the end of the shaft with flat file to remove anyburrs or bulging from the end of the shaft.

• Set the Arbor press according to the shaft it should beless than the diameter of the shaft.

• Select the mandrel according to the shaft it should beless than the diameter of the shaft.

• Select a pair of parallel blocks and position them on thebed of the press.

• Place the pulley with shaft on the parallel blocks, suchthat the shaft in the pulley is in line with the ram of thepress. Ensure that the parallel blocks are as close asto the shaft to give maximum support.

• Apply few drops at oil around the shaft to reduce frictionduring removal.

• Position the mandrel on the shaft and position the ramof the press on the mandrel (Fig 3).

For removing pulley from smaller shaft useArbor press.

For removing pulley from longer shaft or fromthe shaft attached to the machine. Use properpuller.

• Apply light pressure with the ram on the mandrelgradually so that the shaft is extracted out of the pulley.Apply same pressure on the ram still the shaft iscompletely ejected out from the pulley.

• Bring back the ram to its original position gradually andremove the mandrel.

Assemble pulley and shaft

• Deburr the keyway in the shaft and the hub and cleanthe keyways.

• Check the dimensions of the shaft and the hub and thekeyways.



20

• Check, by inserting the hub on the shaft, so that it is atight push fit with the hands on to the shaft. Polish theshaft or scrap bore of the workpiece until this fit isobtained.

• Select a Gib head key of the correct section and length.

• Check the key for width by inserting into the keyway ofthe shaft, draw file the key until it is a light tap fit in thekeyway. Similarly, check the key in the keyway of thehub. (Fig. 4)

• Fit the hub on to the shaft by taping slightly with a softhammer.

• Tap the key in to the keyway. Remove the key andcheck for any high spots, and file away the high spots.Repeat the above operation until the key head isapproximately 15mm away from the boss of the hub.(Fig 5).

• Remove the key and check the fit on the faces.

• Fit key with a firm blow with a hammer.



21


Making and replacing damaged keysObjectives: At the end of this exercise you shall be able to• assemble using feather key in hub and shaft• assemble using tapered key in hub and shaft.


22

Job sequence

• Assemble hub and shaft with parallel key.

• Assemble hub and shaft with tapered (Gib Head) key.

Parallel key fitting

• Deburr the keyways in the shaft and the Hub, clean thekeyways.

• Check the dimensions of shaft and Hub and keywaysusing precision instruments. (Outside dia of shaft,inside dia of hub, length, width and depth of keyway) asper the drawing (Fig 1).

• Select a length of key steel (St 60) of suitable crosssection depending on the size of the keyway.

• File radius at one end of the key and cut to a length plus1 mm of the keyway and file other end of the key(Fig 2).

Ensure that the key is chamfered all around inits bottom side edges.

• Check the key width to suit the keyway in the shaft.Draw file the key, so that it is slight tap fit/light keyingfit (K7-h6) with the keyway on the shaft (Fig 3).

• Check the key for slight tap fit with the keyway in theHub (Fig 4).

• Apply Prussian blue on all sides and bottom portion ofthe key so that proper bearing of key on the keyway isascertained.

• Insert the key in the keyway of the shaft and tap with alight weight soft hammer (Fig 5).

• Tap the hub on the shaft, and remove the hub from theshaft, check the key and note the high spots where thekey has made contact with the keyway of the hub.

• Lightly file the high spots away, the top of the keyshould be approximately 0.1mm clear.

• Repeat the fitting and filing operation until the hub is fiton to the shaft to the desired position (Fig 6).



23


Dismounting, repairing damaged gears and mounting and check for work-abilityObjectives: At the end of this exercise you shall be able to• dismantle gear box from the machine• check out and replace wornout or damaged parts• assemble the gear box• mount the gear box to the machine, check the test run.


24

Job sequenceDismantling the gear box

• Switch of the main power supply

• Inspect the shaping machine gear box.

• Dismantle the guard and belts

• Support the gear box with wooden blanks

• Unscrew the fastener’s by using suitable tools (Fig 1).

Fig 1

FIN

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6H1

• Remove the gear box and keep it on the work table

• Remove the driven pulley from the driver shaft usingpuller. (Fig 2)

Fig 2

FIN

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6H2

• Remove the key from the drive shaft.

• Remove bearing covers and internal circlips.

• Dismantle the driver shaft by tapping the shaft usingcopper rod and hammer.

• Remove the bearings and sliding gear unit from the gearbox by disconnecting spring loaded shifting lever.

• Remove the end nut, bearing covers, circlips and grupscrews in the spacer of the driven shaft. (Fig 3)

Fig 3

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6H3

• Remove the driven shaft by tapping the shaft usingcopper rod and hammer then take out the gears,spacers from the gear box.

• Thoroughly clean all the parts using kerosene andwipped out with cotton cloth. (Fig 3 & 4)

Fig 4

FIN

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6H4

• Check all the part for wear and tear.

• Replace the wornout and damaged parts as needed.

• Lubricate the parts before assemble (Fig 5)

Fig 5

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6H5



25

• Assemble the gear box in reverse manner of dismantle.

• Mount the gear box with the machine.

• Check the test run with different speeds (four speed).

Skill sequence

Inspection of gear tooth elementsObjectives : This shall help you to• check the P.C.D of a given spur gear• check the spur gear tooth thickness• check the teeth clearance between mating gears and backlash• check the concentricity and wear of gears.

Checking of the PCD of the gear

• Select the gear to be measured and place it on the worktable.

• Choose the two standard cylindrical pins or balls formeasuring the gear size.

• Hold the flange micrometer, select and place cylindricalpins or balls as shown in the figure 1.

• Note down the flange micrometer reading by locking itsthimble and barrel scales.

• Find out the PCD by subtracting the pin or ball diameterfrom the obtained micrometer reading.

This method is only suitable for gears havingeven numbers of teeth.

Composite inspection as shown in thefigure 2 is a useful shop friendly tool to determinethe gear size of having any number of teeth.

FIN

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6J1

FIN

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6J2



26

Measuring the gear tooth thickness (Fig 3)

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6J3

CHECKING BACKLASH

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6J4

• Select the gear to be measured and hold it with a vice.

• Hold the gear tooth caliper properly as shown in thefigure 3.

• Adjust the adjustable tongue of the gear tooth caliper totouch it with the tooth side.

• Note down the reading directly from the caliper and it willbe the tooth thickness.

Checking the gear teeth clearance between matinggears and backlash (Fig 4)

Table 1

Backlash Suggestions

Pitch Backlash

3P 0.013

4P 0.010

5P 0.008

6P 0.007

7P 0.006

8-9 P 0.005

10-13P 0.004

14-32P 0.003

33-64P 0.0025

Checking the concentricity and wear of gears (Fig 5)

FIN

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6J5

• Fix the gear to be measured in a mandrel as shown inthe figure.

• Select suitable ball or cylindrical pin and place it inbetween the gap of two teeth.

• Hold the dial indicator in such a way that it will touch theouter periphery of cylindrical pin or ball.

• Note down the dial indicator reading.

• Repeat the same procedure for all the gear teeth andsimultanously note down the dial indicator reading.

• Calculate the total runout or concentricity by subtractingmaximum and minimum dial gauge reading.

• Arrange the gears to be measured as shown in thefigure.

• Hold one gear rigid and insert the feeler gauge throughthe gap between gear teeth of mating gears as shown.

• Note down the feeler gauge reading and it will be thebacklash value.

• Compare the measured backlash value with the giventable and ensure it within the permissible value (limit).



27


Repair & replacement of belts and check for workabilityObjectives: At the end of this exercise you shall be able to• fix a belt on driver and driven pulley• measure tension of a ‘V’ belt drive• adjust belt tension with a spring balance.


28

Job sequence

• Mark and cut the belt to the required length (Fig 1).

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7H1

• Trim both ends of the belt square (Fig 2).

FIN

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7H2

• Fit an alligator fastener centrally into the jaws of thelacing machine and fit the pin into the side of the jawsto hold the fastener in the machine (Fig 3).

FIN

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7H3

• Put the belt centrally between the jaws of the machine.(Fig 4)

FIN

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7H4

FIN

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7H5

FIN

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7H6

• Operate the machine to press the fastener into the beltuntil it is flush with the belt (Fig 5 & 6). Trim the edgesof the fastener.

• Place the belt around the shafts beside the pulleys withthe rough side against the pulleys and join both ends bythe pin (Fig 7).

• Fit the belt to the small pulley end first and then run iton to the big pulley (Fig 8).



29

FIN

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7H7 FIN

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7H8

Skill sequence

Adjust belt tension in ‘v’ belt driveObjectives : This shall help you to• check belt tension using a spring balance• adjust belt tension by tensioning bolts.

Measure the longest span length of the belt between thepulleys, using a steel tape.

Find the middle of the longest span of the belt between thepulleys.

Push this mid-point inwards, then pull it out and note thetotal deflection. (Fig 1)

This indicates the existing tension of the belt.

Loosen the lock-nuts. (Fig 2)

Slacken the clamping bolts. (Fig 2)

Move the pulley with the adjusting screws to alter thetension. (Fig 2)

The adjusting screws must be turned equally tokeep the pulleys correctly aligned.

Attach a spring balance and check the tension of the belt.(Fig 3)

Readjust the adjusting screws untill the tension is correct.

Tighten the clamping bolts.

Tighten the lock-nuts.



30


Making of template / gauge to check involute profileObjectives: At the end of this exercise you shall be able to• mark dimensions with a vernier height gauge for Task 1 and 2• mark angles with a vernier bevel protractor for Task 1 and 2• make relief by hacksawing• file external and internal ‘V’ to an accuracy of ± 10 minutes.



Job sequence

TASK 1: Angle gauge

• Check the raw material for its size

• File and finish the plate to size 60 x 20 x 3.8mm(0.4mm thick for grinding allowance

• Mark centre lines for the 60° external Vee and reliefgrooves.

• Mark centres for 2 mm relief hacksawing.

• Cut off excess metal with a hacksaw from the plate, forthe two 'V' grooves.

• Ensure that punch marks are visible and sufficientmetal is left for finish filing

• File and finish the sides of the groove with a knife edgefile

• Ensure that the width of the remaining metal on bothsides of the 'V' grooves end is equal.

• Check the accuracy of the 60° angle with the template/ gauge supplied.

• Repeat the steps for the 'V' groove.

• Cut off excess metal from the plate for external 'Vee' onone side.

• File and finish the side of the 'VEE' correct to the centreline.

• Cut off excess metal from the other side of 'Vee'

• File and finish the 'Vee' to the centre line

• Check the 60° & 45° angle with a vernier bevel protractorfile, and finish all the edges.

• Remove burrs and check the dimensions.

TASK 2: Template of different profiles

• Check the raw material for it s size

• Remove burrs and check the raw material size.

• File the large surface with a 200mm flat second cut file(Hold the sheet on the wooden block)

• File two adjacent sides - flat and square.

• Make relief hole by drilling as per drawing.

• Mark dimensions as per drawing.

• Hacksawing and remove the excess material.

• File and finish the remaining surfaces (60mm) to sizeand check the size.

• File and finish external and internal 60° angles andradius check with vernier bevel protractor and gauge.

• File and finish thickness to 3 mm, by fixing work on thewooden block.

Care should be taken to maintain the correctlength

_ _ _ _ _ _ _ _


32


Repair of broken gear tooth by stud and repair broken gear teeth by dove-tailObjectives: At the end of this exercise you shall be able to• repair gear tooth by stud and welding method• repair gear tooth by dovetail method.


33

Job sequence

TASK 1: Repair broken gear tooth (dovetail blank method)


• Support the gear against a Vee block and clamp it byparallel clamp.

• Mark the dovetail groove on the gear wheel from bothsides using a vernier height gauge and vernier bevelprotractor.

• Punch the marking lines (Fig 1).

• Drill 3mm dia. relief holes one each on the corner of thedovetail.

• Remove material from the gear to shape and size ofdovetail as per marking (Fig 2).

• File the blank to the profile of the gear tooth as per punchmark.

• File the dovetail portion of the blank.

• Fit the blank into the dovetail groove of the gear wheel.If necessary, file the blank till it fits in.

• Apply Prussian blue on the dovetail groove to check thehigh spots in the blank piece.

• Remove the high spots and make a snug fit in thedovetail groove.

• Drill 5.9mm dia. - 2 holes up to a depth of 33mm on theblank and gear wheel in assembled condition.

• Ream the holes using a hand reamer.

Dismantle the assembly and remove the chipsfrom the holes of the gear and the blank.

• Assemble again and fit the dowel pins in the holes bya slight tapping.

• File the profile of the gear tooth to the correct shape.

• Use a template to check the profile.

File the sides of the blank, flush with the gear.

TASK 2: Repair broken gear tooth (Welding method)

• File the broken tooth surface flat (Fig 1). • Mark for four holes on the surface with 10mm centredistance between the holes.

• Punch the centres for drill holes (Fig 2).

_ _ _ _ _ _ _ _



• Drill 5 mm dia. holes on the centres to a depth of 9 mm.(Fig 3).

Remove the chips from the holes.

• Tap the holes using a M6 hand tap (Fig 4)

Remove the chips and clean the tapped holes.

• Fix up four hexagonal headed M6 bolts into the tappedholes and tighten them securely (Fig 5)

• Cut off the hexagonal head of the bolts by hacksawing.

• Build up material by welding just enough to make thetooth profile by filing (Fig 6).

• File the built up material to tooth profile. Use a templatefrequently to check the profile to have correct shape andpitch (Figs 7 & 8).


35


Make hexagonal slide fittingObjectives: At the end of this exercise you shall be able to• file and finish matting parts within +0.02 mm using O.S.micrometer• file and finish mating parts having angular surfaces within +10’ accuracy using vernier bevel protractor.


36

Job sequence


• File the surface and two adjacent edges at right angleto each other.

• Check the squareness.

• Refer the job drawing and do the marking as per thedimensions given (Fig 1).

• File the excess material and maintain the dimension70mm with vernier caliper.

• Check the squareness with square head.

• To make the hexagonal cut out, drill a 22 or 23mm dia.drill hole in the centre. File the hexagonal shape witha square file or triangular file (Fig 1).

• At this stage make 6 relief hole in the corners by ∅3mm drill.

• Finish the hexagonal shape and check the angle by thehelp of protractor head. (120°)

• Check the dimension in side and parallelism of faceswith a vernier caliper.

• File the end of the given rod at right angle to the axis.

• Mark the hexagon as per the dimensions given in thedrawing (Fig 3).

• File one side up to the marked line. Check the parallelismthrough out the length.

• File the adjacent side and check the angle (120) byprotractor head.

• File and finish the other sides also (Fig 4).

• Finally check the flat dimension and other sizes andassemble in the hexagonal slot.

• Place the female part on a wooden block. File andfinish both surfaces with a smooth file and maintain thethickness.

• Remove the burrs from the edges. `

Skill sequence

Marking using vernier height gaugeObjective: This shall help you to• mark with a vernier height gauge.

What is the main function of a vernier height gauge?

One of the main functions of the vernier height gauge is toscribe lines on a workpiece to known heights.

How to use a vernier height gauge?

The height gauge scriber must be checked against thereferences surfaces to confirm whether the zero of thevernier coincides with the zero of the beam scale when thescriber contacts the references surfaces. (Fig 1)

Check the free movements of the sliding unit.

Make sure that the workpiece has no burr and has beenproperly cleaned.

Workpiece necessitates clamping to an angle plate if it isthin.

The application of the marking media sholud be light, thinand even.



Keep the vernier height gauge base firmly on the surfaceplate.

Hold the scriber at an angle to the workpiece, and pull thecorner of the scriber across the work (Fig 2).

Do not allow the base to lift.

Do not apply too much pressure to peel off metal from theworkpiece. This will avoid damage to the scriber point.Centre points can be located by scribing lines at rightangles.

Scirbe first all lines of dimensions in one direction (Fig 3).

Place the work at 90 degrees and scribe the lines todimensions to intersect one another. (Fig 4)

Work surfaces should be finished flat and smooth to avoidlifting during marking.

Precautions to get exact lines

Ensure the scriber point is sharp always. Sharpen only theinclined surface of the scriber point (Fig 5).

Frequent sharpening should be avoided. Ask the instructorto sharpen the scriber for you.


38


Prepare different types of documentation as per industrial need bydifferent methods of recording informationObjectives: At the end of this exercise you shall be able to• prepare and fill up batch processing record in format• prepare and fill up bill of materials (BOM)• prepare and fill up production cycle time in format• prepare and fill up daily production report in format• prepare and fill up manufacturing stage inspection report format.

Note:

• Instructor/ Training Officer should arrange for a industrial Visit near by your institute, collect inputs andfill up format as required.

• Trainees will be guided by the concerned instructor/ Training Officer.

• Collect necessary information forms and instruct the trainees to reproduce the format and guide themto fill it up.

Job sequence

• Study the different types of documentationprovided in (format).

• Visit to the industry and collect the input /information from industry and fill it up in all theformat.

• Prepare the required format with the knowledgegained during the industrial visit.

• Record relevant information in the format.

• Get it check by your Instructor / Training Officer.

TASK 1: Documentation 1


39

BATCH PROCESSING RECORD - FORMAT - 1

Batch Processing Record

Description of job Batch no. :

Part no. : Batch quantity :

Name of part : Batch record no. :

Purchase order no. :

Description of process :

Manufacturing Organisation :

Period of manufacture (Year - Qtr): Start date of manufacture: End date of manufacture:

Number of pages according to batch: Inserted pages: Manufacturing facilities:

Total number of pages

1. Operator / TechnicianDate Name and signature

2. Production in-charge:Date Name and signature

3. Section managerDate Name and signature

4. Plant in-charge:Date Name and signature

5. Production in-charge:Date Name and signature

Remarks (if any)



40

BILL OF MATERIAL (BOM)- FORMAT-2

(as per IS: 11666 - 1985)

Date:

Place: Incharge

S. No. Item No. Description Quantity Reference Material as Remarks dwg no. per standard



41

PRODUCTION CYCLE TIME - FORMAT-3

Organisation Name: Process: Line Incharge: Date/Time:

Department / Section:

Operator: Machine Cycle Notes Time

Operations Sequence Observed Times Lowest Repeatable



42

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43

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44

TASK 2: Documentations - 2Objectives : At the end of this exercise you shall be able to• prepare and fill job card in format• prepare and fill work activity log in format• prepare and fill batch production record• prepare and fill estimation sheet in format• prepare and fill maintenance log in format• prepare and fill the history sheet of machinery and equipment in format• prepare and fill maintenance record in format.


Note:

• Instructor / Training Officer should arrange for a industrial visit near by your institute, collect inputsand fill up in format as required.

• Trainees will be guided by the concerned instructor/ Training Officer.

• Collect necessary information forms and instruct the trainees to reproduce the forms and guide themto fill it up.

Job sequence

• Study the different types of documentation providedin (format).

• Visit to the industry and collect the input/ informationfrom industry and fill it up in all the format.

• Prepare the required format with the knowledgegained during the industrial visit.

• Record relevant information in the format.

• Get it checked by your instructor/ Training Officer.


45

JOB CARD - FORMAT-1

Doc No.

Job Card Rev No.

Date

Order Starting Date

Customer

Work Order No.

Details

S.No. Date Production Line Time (Minutes) Location Remarks Description Start Time End Time Total Time Time




WORK ACTIVITY LOG - FORMAT-2

Organisation Name:

Department:

Section:

Employee Name:

Supervisor Name:

Date:

Start / Stop Operations Equipment / Machinery/ Remarksperformed Instruments used

8.00 to 9.00 a.m.

9.00 to 10.00 a.m.

10.00 to 11.00 a.m.

11.00 to 12.00 noon

12.00 to 1.00 p.m.

1.00 to 2.00 p.m.

2.00 to 3.00 p.m.

3.00 to 4.00 p.m.


47

BATCH PRODUCTION RECORD - FORMAT-3

Batch Production Record in accordance with batch processing record

Manufacturing Organisation Name: _______________________

Description of job: ______________________

Name of part: __________________________

Batch No.: ____________________________

The following deviations have appeared (continued)

No. process Name of processing step Documented Short description step page no. of deviation

1 Raw material preparation:

Operation 1: _____________ 1. _____________

Operation 2: _____________ 2. _____________

Operation 3: _____________ 3. _____________4. _____________

2 Sizing of material:

Operation 1: _____________ 1. _____________

Operation 2: _____________ 2. _____________3. _____________



48

ESTIMATION SHEET - FORMAT-4

Part Name: ___________________ Part No.: _____________ Part Drawing

Assembly: _________________ Material: ______________

Assembly No.: ______________ Stock size: ____________

Operation Operation Machine Estimated Rate / piece Tools No. description time per hr.

Prepared by: ________ Date: _________

Approved by: ________



49

MAINTENANCE LOG - FORMAT-5

S. No. Date Nature of fault Details of rectification Signature of in-charge done

Organisation Name :

Department :

Section :

Name of the machine :



50

MACHINERY AND EQUIPMENT RECORD - FORMAT-6

Organisation Name :

Department :

Section :

History sheet of machinery & Equipment

Description of equipment

Manufacturer’s address

Supplier’s address

Order No. and date

Date on which received

Date on which installed and placed

Date of commissioning

Size: Length x Width x Height

Weight

Cost

Motor particulars Watts/H.P./ r.p.m: Phase: Volts:

Bearings/ spares/ record

Belt specification

Lubrication details

Major repairs and overhaulscarried out with dates



51

PREVENTIVE MAINTENANCE RECORD - FORMAT-7

Organisation Name :

Department :

Section :

Name of the Machine : Location of the machine :

Machine Number :

Model No. & Make :

Check list for machine inspection

Inspect the following items and tick in the appropriate column and list the remedial measures for thedefective items.

Items to be checked Good working/ satisfactory Defective Remedial measures

Level of the machine

Belt/chain and its tension

Bearing condition (Look, feel,listen noise)

Driving clutch and brake

Exposed gears

Working in all the speeds

Working in all feeds

Lubrication and its system

Coolant and its system

Carriage & its travel

Cross-slide & its movement

Compound slide & its travel

Tailstock’s parallel movement

Electrical controls

Safety guards

Inspected by

Signature

Name:

Date: Signature of in-charge



52


Marking out on the round sections for geometrical shaped fittings such asspline with 3 or 4 teeth. Finishing and fitting to size, checking up the facesfor universalityObjectives: At the end of this exercise you shall be able to• mark and file spline on the shaft• mark and file internal spline in the hub• file and assemble hub and spline shaft.


53

Job sequence• Check the raw material size using steel rule.

• File raw metal to over all size part 1 ∅ 28 - 50mm andpart - B ∅ 50 - 50mm.

• Apply marking media on part 1 and part 2.

• Mark off spline key ways on part 1 and 2 by keeping on‘V’ blocks using vernier height gauge and try squre asper job drawing.

• Punch witness mark on part 1 and part 2.

Part 1

• Cut and remove the excess metal in Part 1 byHacksawing and chipping and file to size and shapeusing flat file, safe edge file, square file and half roundfile bastard, second cut and smooth grade of files.

• Check the spline shaft size using vernier caliper.

Part 2

• Hold the part 2 in drilling machine table.

• Fix centre drill in drilling machine spindle.

• Drill centre drill, to locate centre of the round rod.

• Remove centre drill and fix ∅ 6mm drill in drillingmachine spindle and drill pilot of the hole.


• Similarly, enlarge the pilot hole using different diameterdrill and finally drill ∅ 20mm and enlarge the hole.

• Hold the job in benchvice and file key way slot size10mm width X 4mm depth using square file bastard,second cut and smooth grade of file.

• Similarly, file other three keyways slot to the size asper job drawing.

• Check the key way slots sizes using vernier caliper.

• Finish file on part 1 and 2 as shown in job drawing andslide it (Fig 1).

• Apply thin coat of oil and preserve it for evaluation.

Skill sequence

Marking of a job with vernier height gaugeObjective : This shall help you to• mark concentric and eccentric centre lines of a job by using a vernier height gauge.

The height gauge marking is more accuratethan the scribing block marking.

The marking surface must be free from sharpedges and unevenness.

Clamp the finish turned rod in the ‘V’ block with the help ofthe clamps.

Apply marking media on both faces of the job.

Set the scriber point on the top edge of the job (Fig 1).

Move the height gauge scriber over the round surface to geta feel that the scriber bottom face is contacting the workperiphery (Fig 1).

Lock the slides and note down the reading of the scales.


54

Subtract half the diameter from the reading and set theheight gauge for that reading. (Fig 2)

Scribe a horizontal line on both faces. (Fig 2)

Clamp the workpiece to the ‘V’ block.

Scribe horizontal lines on both faces with the same readingwhich is set for centre position. (Fig 4)

Add eccentricity amount to the above reading and reset theheight gauge for the new reading. (Fig 4)

Scribe horizontal lines on both faces. (Fig 4)


Release the workpiece from the clamp and rotate theworkpiece through 90°. Set the line at 90° with the help ofa try–square. (Fig 3)

Release the workpiece from the ‘V’ block.

Punch mark on both sides both concentric and eccentriccentre points.

Checking parallelism using dial test indicatorObjective : This shall help you to• check parallelism of faces using a dial test indicator.

Checking Parallelism

For checking parallelism and flatness of surfaces, dial testindicators are mostly used.

Procedure

Assemble the dial test indicator on the stand.

Ensure that the surface plate and the dial test indicatorstand base are cleaned.

Remove burrs from work surface, and clean.

Use fine cotton cloth for cleaning.

Check the free movement of the plunger. (Fig 1)

Place the workpiece below the dial test indicator and setthe plunger.

A half-turn pressure of the pointer will be adequate. Theplunger should be perpendicular to the work surface.(Fig 2)



Unlock the bezel clamp. Set the reading to zero.

Slide the workpiece on the surface plate below the dial testindicator. (Fig 3)

Note the reading.

Repeat the same step at three places longitudinally andtransversely.

Note the reading and determine the differences. (Fig 4)

Precaution

Do not apply oil on the plunger of the dial testindicator.

Avoid sudden jerks to the plunger.


56

Production & Manufacturing Exercise 4.3.173Fitter - Hydraulics and Pneumatics

Identify pneumatic components - Compressor, Pressure gauge, Filter - Regu-lator- Lubricator (FRL) unit - Different types of valves and actuatorsObjectives: At the end of this exercise you shall be able to• identify the pneumatic components• enter the name of the parts in table 1.


57

Job sequence

Instructor shall arrange and show thecompressure to trainees and give demoexplaining all the parts. Ask the trainee torecord in the Table 1.

• Observe the compressor.

• Identify the parts.

• Record the parts name in Table 1.

Table 1

Serial No Name of the parts

1

2

3

4

5

6

7

8

9

10

11

12

• Get it checked by your instructor.


58


Dismantle, replace and assemble FRL unitObjectives: At the end of this exercise you shall be able to• overhaul FRL unit• mount and read pressure on the pressure gauge.


59

Job sequence

• Overhauling a filter of FRL unit and Lubricator.

• Drain the water from the filter unit. (Fig 1)

• Hold the FRL unit in a bench vice in a horizontal positionbetween soft jaws.

• Drain water from lubricator, by rotating drain plug.(Fig 1)

• Hold the filter bowl with hand and unscrew it.

• Do not use pipe wrench since bowl (mostly of plastic)may break/damage.

• Use a spanner and remove the filter insert.

• Rinse the filter in clean kerosene.

• Blow the inner side of filter using compressed air.

• Rinse the bowl in soap solution and dry it with cleancloth.

• Place the filter insert and tighten the nut.

• Screw the bowl to the housing.

• Confirm the drain plug is in closed condition.

Skill sequence

Overhauling a lubricator of FRL unitObjective: This shall help you to• overhaul lubricator.

Hold the lubricator body and unscrew the bowl by hand.(Fig 1)

Drain oil from bowl.

Clean the bowl and rinse it in soap solution.

Dry it with a clean cloth.

Clean the filter at the tip of the dip tube. (Fig 1)

Ensure dip tube in its location.

Screw the bowl into it position tightly.

Open the inlet valve.

Observe the pressure gauge.

Fill it with correct grade of oil as per manufacturersrecommendation to the level marked.

Maintain oil level.

Do not fill above or below the marked level. (Fig 1)

Mounting and reading of pressure

Mount the FRL unit on the trainer kit.

Ensure the flow of air is in line with arrow mark on the FRLunit.

Needle of pressure gauge indicates the pressure on thedial behind it. (Fig 2)

Pressure is measured in kg/cm2 or kgf/cm2.



60


Demonstrate knowledge of safety procedures in pneumatic systems andpersonal protective equipment (PPE)Objectives: At the end of this exercise you shall be able to• follow the safety while working in pneumatic system• select the personal protective equipment.


61

Job sequence

• Should not operate pneumatic machine withoutknowledge.

• Protect your self and others from the damaging effect ofcompressed air.

• Inspect the air hose for cracks or other defects.

• Before opening the control valve,see that nearbypersonnel are not in the path of the air blow.

• Never stay near to compressed air.

• Do not turn the main air supply on make sure that, thedisconnected pipes are connected properly, otherwisedisconnected pipe can whip around and cause injury.

• If air is leaking from a joint, close the air valveimmediately.

• Always turn air off before altering the circuit.

• Keep your hands away from the piston rods.

• Wear personnel protective equipment. The detailedinformation has been aiready given in safety precautions.



62


Identify the parts of a pneumatic cylinderObjectives: At the end of this exercise you shall be able to• identify pneumatic elements from their outlook• enter the name of the part in table - 1.


63

Job sequence

Instructor shall arrange and display thepneumatic cylinder and give demo to traineesshowing all the parts. Ask the trainees torecord in the table-1.


• Observe the given pneumatic cylinder.

• Identify the parts.

• Record the part name in Table. 1

Table. 1

Serial No Part Name

1

2

3

4

5

6

7

8

9

10

11

12



64


Dismantle and assemble a pneumatic cyclinderObjectives: At the end of this exercise you shall be able to• dismantle the pneumatic cylinder• clean and inspect the parts for wornout and damage parts• assemble the pneumatic cylinder• test the cylinder for proper function.


65

Job sequenceDisassembly

• Disconnect air and electrical connections to the cylin-der assembly and remove the cylinder from machine.

• Remove and retain air lines and any other accessoryitems(solenoid valve, flow controls, etc.) from the cylin-der assembly.

• Scribe an index mark on both end caps to showorientaiton to each other. These marks will assist whenre-assembling the cylinder (Fig 1).

• Remove and retail all the rod nuts, lock washers and tierods from the cylinder end caps. Remove the end capsfrom the cylinder tube and discard the cylinder gaskets.(Fig 2).

• For single-acting cylinders : Use a strap wrench orsoft-jaw wrench to hold the piston rod at the knurledsurface. Remove and discard the self-locking nut, O-ring, and piston. (Fig 3)

• For double-acting cylinders : Use a strap wrench orsoft-jaw wrench to hold the piston rod and remove andretain the nut and washers. Note two different styles ofpiston nut in figure. Discard the piston (Fig 4).

• Remove and retain the E-ring and miscellaneous hard-ware from the piston rod and pull the front end cap fromthe piston rod (Fig 4).

Prior to removing the end cap, remove anyburrs or nicks from the piston rod surface withfine emery cloth (400 grit). Remove all emerydust before removing the front end cap.

• Remove and retain the two screws, lock washers andthe piston rod plate from the front end cap. Remove anddiscard the packing ring and the O-ring (Fig 5).

• Remove and retain the jam nut and spacer from thespeed adjusting screw in the front end cap. Do notremove the adjusting screw. Remove and discard theO-ring.(Fig 6)



66

• Some rear end caps on single-acting cylinders maycontain speed adjusing screws. If so, remove and retainthe jam nut and spacer from both adjusting screws. Donot remove the adjusting screws. Remove and discardthe O-rings.

• Clean all metallic parts thoroughly with a solvent(mineralsprits recommended).

• Do not soak parts in solvent. Do not clean the sphericalrod end bearing with solvent as this will remove lubricantfrom the bearing.

Do not use trichlorethylene or chlorinatedhydrocarbon solvents. Do not clean or soakO-rings or other rubber components in solvent.

• Inspect the inside surface of the cylinder tube andreplace if the I.D. is worn out or if there are deepscratches or grooves on the inner surface.

Re-assembly

• Install a new O-ring to the speed adjusting screw on thefront end cap. Replace the spacer and jam nut.

• If equipped with speed adjusting screws on the rear endcap; install new O-rings. Replace the spacers and jamnuts.

• Install a new packing ring and O-ring and attach thepiston rod plate to the front end cap with lock washersand screws.

• Be sure the piston rod is free of nicks and burrs. Slidethe front end cap onto the rod and install the E-ring.

• Assemble the new U-seal and O-ring on the piston, thenmount the piston and O-ring on the piston rod andsecure with a new lock nut. See Fig 3.

• Mount ‘E’ ring, washer, piston, washer seal, washerand lock washer on the piston rod. The rubber face of

the piston should face towards the rod and bearing.(Fig 4)

• Apply a light coat of grease to the cylinder tube I.D.,completely around the U-seal, (if double-acting, applyaround piston edge), the front end cap gasket, andworking length of the piston rod.

• Install new cylinder gaskets on the end caps.

• Assemble the cylinder tube, rear end cap and front endcap assembly. Install the tie rods, tie rod nuts and lockwashers. Finger tighten the nuts. Then cross tighenthe nuts equally and then tightened to a final torque.(Fig 2)

Before tightening the nuts, be sure the tie rodsare parallel to the long axis of the cylinder. Tierods must be positioned properly to obtain agood seal at both end caps.

• Re-attach accessory items and aiir lines to the cylin-der.

• Re-install the cylinder in the machine and connect airand electrical lines.

• Verify proper operation of the cylinder.

Testing the cylinder

• Apply air to the inlet port on the front end cap. Use abrush with a soap and water solution to check for leaks.Do not submerge the cylinder.

• With air applied to the speed fitting and the piston rodfully extended, open the air passage in the speed fittingand observe that the piston moves to the rear cap.Check for leakage at the front cap adjustment screw; atthe front cap ppiston rod seal; at the rear cap adjust-ment screw and adjacent ports (if equipped); from thepiping between the speed fitting and the front end cap;from both ends of the cylinder at the cap gaskets; andfrom the speed fitting exhaust port. Repair any leaksand recheck.



67


Construct a circuit for the direction & speed control of a small bore singleacting (s/a) pneumatic cylinderObjectives: At the end of this exercise you shall be able to• select the components, to operate Single Acting Cylinder using 3/2 way valve• draw circuit diagram on paper• assemble circuit on the trainer board• check function of the circuit.

Job sequence

TASK 1 List the components,to operate Single Acting cylinder using 3/2 way valve.

Requirements

Tool / Instrument / Equipment / Machines

• Trainer board - 1 No.• Pneumatic source - 1 No.

Material / Component

• P U Tube - as req• Paper - as req.• Pencil - as req• Single Acting Cylinder - 1 No• 3/2 way valve - 1 No• FRL - 1 No

1 Identify the components and list using ISO 1219symbol in the table.

The instructor shall arrange trainer board withcomponents mentioned

Component Symbol

Pneumatic Source

Single Acting Cylinder

3/2 Way valve

FRL


68

TASK 2: Draw circuit diagram. (Fig 1)

TASK 3: Assemble circuit on the trainer board

1 Arrange component on trainer board as shown.

2 Connect source to FRL

3 Connect FRL to input port “1” of 3/2 Way valve.

4 Connec t output port “2” of 3/2 Way valve to input portof single acting cylinder.

5 Ensure proper connections.

6 Supply air.

Correct the assembly if air leaks through joints

TASK 4: Check function of the circuit per the table

Action Expected Result Confirm Result (Put )

Press Push Button Piston moves forward

Release push Button Piston retracts

Conclusion

Conclusion drawn Remarks

Motion of Single Acting cylinder can be controlled by3/2 Way valve.



69

Connect tube using push in fitting

1 Grip pull back ring. (Fig 2)

2 Pull the ring. (Fig 3)

3 Push the P U (poly (Urethene) tube into fitting. (Fig 4)

4 Push lock ring forward to lock. (Fig 5)



70

RequirementsTool/ Instrument/ Equipment/ Machines

• Trainer board - 1 No.• Pneumatic source - 1 No.

Material/ Component

• P U Tube - as req• Paper - as req.• Pencil - as req• FRL - 1 No• 5/2 way valve - 1 No


Construct a control circuit for the control of a d/a pneumatic cylinder withmomentry input signalsObjectives: At the end of this exercise you shall be able to• select the components,to operate single acting cylinder using 5/2way valve• draw circuit diagram• check function of the circuit.

PROCEDURE

TASK 1:Select and list the components,to operate double acting cylinder using 5/2 way valve.

1 Identify the components and list using ISO 1219symbol in the table. The instructor shall arrange trainer board with

components mentioned

Component Symbol

Pneumatic Source

Single Acting Cylinder

3/2 Way valve

FRL


71

TASK 2: Draw circuit diagram. (Fig 1)

TASK 3: Assemble circuit on the trainer board

1 Arrange component on trainer board as shown.

2 Connect source to FRL

3 Connect FRL to input port “1” of 5/2 Way valve.

4 Connect output port “2” & “4” of 5/2 Way valve to inputport “A & “B” of double acting cylinder.

5 Ensure proper connections.

6 Supply air.

Correct the assembly if air leaks through joints

TASK 4: Check function of the circuit. ( Table I)

Action Expected Result Confirm Result ( Put )

Press push button Piston moves forward

Release push button Piston retracts

Conclusion

Conclusion Drawn Remarks

Motion of double acting cylinder can be controlledby 5/2 way valve.



72


Construct a circuit for the direct & indirect control of a d/a pneumatic cylin-der with a single & double solenoid valveObjectives: At the end of this exercise you shall be able to• construct a circuit• select the component• assemble the circuit on the trainer board• check the function of the circuit.

PROCEDURE

TASK 1: Construct a circuit for the indirect control of a double - acting pneumatic cylinder with a doublesolenoid valve.

RequirementsTool/ Equipment/ Machines / Component

• Double acting cylinder• 5/2 DC double solenoid valve (y1 y2)• Shut - off value• Filter regulator unit

• Pneumatic power source• Push button (PB1, PB2)• Relay (K1,K2)


74

TASK 2 : Construct a circuit for the direct control of a double-acting pneumatic cylinder with a double solenoidvalve.



75

TASK 3 : Construct a circuit for the indirect control of a double-acting pneumatic cylinder with a single solenoidvalve.



76

TASK 4: Construct a circuit for the direct control of a double - acting pneumatic cylinder with a single solenoid valve.



77

Job sequence

• construct circuit diagram

• Assemble circuit according to circuit diagram

• carry out the exercise

Practice exercise

Set the following

• operating pressure p (50 bar)

• one - way throttle valve,position 2

Enter the following in the table

• flow paths,operating positions

• pressures po2 and po3

• forces F1 and F2 and Δ F (to be calculated)

Hydraulic 4/2 way valve I pressure bar force kgf or daN effective force kgfcylinder or daN

d F = F1 - F2

flow operating ρρρρρo2 ρρρρρo3 piston rod piston rodpaths positions side F1 side F2

forwardstroke

returnstroke

Safety precautions

Only switch on the power unit upon directions from theinstructor.

Make sure the standing area is safe. Do not spill any oil.Do not work with oily hands (danger of slipping off). Faultfinding and dismantling only when the system has beendepressurized.



78


Dismantling and assembling of solenoid valvesObjectives: At the end of this exercise you shall be able to• remove the nut to remove the coil• remove the cores / metal plate• remove the valve• check for scratches• clean and reassemble.


79

Job sequence• If you ever need to disassemble a 2P025-08 Solenoid

Valve,here’s a step by step pictorial.

The assembled valve looks like

• First thing to note is that the valve actually is two majorcomponents. The coil and the valve mechanism. Youcan safety remove the coil even while the valve itself isconnected to the water supply and under itself isconnected to the water supply and under pressure.Removal of the coil itself will not cause the water to flowand will not cause the valve to leak water.

Remove the top nut to remove the coil

• For the following steps are disassembling the valveitself. For this you need the water turned off and eventhen you will get a slight amount of water out of thesystem when you take the valve apart.

• Here,note the two screws holding the metal plate on.We will remove these to disassemble the valve.

• Now remove the two screws.

• Now remove the metal plate.

• Now with a twisting motion,grab the valve stem and pullit upward.

• The valve with the stem removed.

• Now the stem itself can be disassembled (and cleaned).Note that the plunger (with the spring) should just fall outof the stem.

• Observe inside the stem and the surface of the plungerand clean any trace of foreign objects.


Fig 5

Fig 4

Fig 3

Fig 1

Fig 2



Fig 8

Fig 9

Fig 7

Fig 6


81


Demonstrate knowledge of safety procedures in hydraulic systems (demoby video)Objectives: At the end of this exercise you shall be able to• follow all the safety knowledge• ensure safety for personal and machine.

Instructor shall arrange video locally and demonstrate to the trainees.


82


Identify hydraulic components - Pumps, Reservoir, Fluids, Pressure reliefvalve (PRV), Filters, different types of valves, actuators and hosesObjectives: At the end of this exercise you shall be able to• identify and locate the element in a hydraulic circuit• draw symbols as per ISO 1219.


83

Job sequence

Instructor shall arrange and display the circuitand demonstrate to trainees.


• Study the circuit and record the part name in Table - 1

• Draw the symbol against the part name.

Table. 1

Serial No Part Name

1

2

3

4

5

6

7

8

9

10

11

12



84


Inspect fluid levels, service reservoirs, clean/ replace filtersObjectives: At the end of this exercise you shall be able to• identify the various hydraulic elements used in power pack• remove, clean and assembe of inlet filter• preparing the power pack for operation• start and set the pressure in the power pack.


85

Job sequence• Locate the power pack of the hydraulic system.

• Ensure the system is in ‘off’ condition.

• Remove the top cover of the power pack after unscrewingthe fastening bolts (Fig 1).

• Pipes are provided below the top cover; place it carefully.

• Place the top cover upside - down with the variouselements mounted on it carefully on the workbench(Fig 2).

• Identify the various elements, their names and function.Also observe the order of connection.

• Keep the reservoir closed with a plastic cover to aviodcontamination. Remove clean and assemble the inletfitter. Prepare the power pack for operation. Set thepressure of relief valve.

Skill sequence

Removing, cleaning and assembling of inlet filter (for a closed type ofreservoir with removable top cover)Objective: This shall help you to• dismantle, clean and assemble inlet tilter.

Inlet filter is normally called as suction strainer. Unscrewthe inlet cartridge (Fig. 3), wipe at the excess sludgecollected on the filter.

Soak it in kerosene and remove the studge.

Flush the strainer with clean kerosene (Fig 4).

Blow compressed air on the mesh area.

Clean the mounting area of the strainer.



86

Screw the strainer back in its location.

Strainer/Filters should be clean periodically as per recom-mendation.

Replace with new filter, if the existing filter damaged.

While replacing new strainer, care should be taken toselect the correct strainer.

Checking the gasket of the top, cover of the reservoir forproper seating (Fig 5).

Place the top cover of the reservoir in its place.

Mount the cover by screwing the fastening screws.

Now inspect the cover for proper seating all over.

Preparing the power pack for an operationObjective: This shall help you to• prepare the power pack for an operation.

A power pack can perform well only if it is in an idealcondition. So before putting on a hydraulic system, thepower pack should be checked for it prepareness.

Check the proper mounting of all units.

Check the coupling between motor and pump for freeness,before mounting the top plate.

Check and confirm oil level (Fig 6).

If oil level is less than the mark, fill the correct grade of oil.

Keep the reservoir clean and clear all unnecessary thingsaround and underneath the reservoir.

Check for proper tightening of all connecting hoses.

Check whether the breather is placed properly.

Oil drain hole is plugged and no oil leakage.

Starting and setting the pressure in a power pack

Objective: This shall help you to• starting and setting the pressure in a power pack.

Switch on the electric motor of the power pack.

Confirm no loose ends of pipes exist before switch on themotor.

Observe and confirm the direction of rotation of the motoras indicated in the motor body (Fig 7).

Put off the motor if it rotates in the opposite direction andcall electrician.

Observe the pressure in the pressure gauge.

Now get the required pressure on the pressure relief valve(Fig 8).

Rotate clockwise to increase pressure and vice versa.Production & Manufacturing: Fitter (NSQF Level - 5): Exercise 4.3.184


87

Removal of an inlet filterObjective: This shall help you to• removal of an inlet filter.

The procedure for removing the inlet filter depends on theconstruction of the power pack. The suction strainer isusually placed immersed in the oil and locating it needssome experience.

Open type of reservoir (Fig 9)

In a open type reservoir, the steps to be followed are

Put off hydraulic system.

Remove the top cover plate.

Keep your hand clean.

Insert your hands inside the oil and locate the suctionstrainer.

Use a suitable spanner and loose the suction strainer.

Clean the strainer using kerosene and blow with com-pressed air.

Check for damages, if any replace with new filter.

Screw on the clean filter back into position.

Removal of filter in a closed type of reservoir

Already the procedure for the filter of a closed type ofreservoir with removable top cover has been explained.Other type of reservoir is explained below.

All sides welded reservoir (Fig 10)

Put off the hydraulic system.

Drain the oil from the reservoir.

Remove the inspection cover after unscrewing mounting.

Locate and unscrew the suction strainer.

Clean, strainer with kerosene and blow it with compressedair.

Clean inside of the reservoir thoroughly.

Screw the suction strainer after inspecting it for damages.

Replace inspection cover and gasket, tighten mountingscrews.

Refill the oil in the reservoir after filtering the oil using mesh.

Check for oil leakage through inspection cover. Confirm noleakage of oil.

Check for oil level.



88

Now the system is ready for use.

Externally mounted suction strainer (Fig 11)

To dismantle this type of suction strainer the steps areas follows

Put off the hydraulic system.

Unscrew both the cap nuts of the lines coming to the filterunit and going out of it.

Hold the filter unit in the benchvice and unscrew themounting bolt. (Fig 12)

Remove the filter insert clean/replace filter insert.

Clean the casing thoroughly.

Place the insert and screw the mounting bolt.

Mount the filter unit back in this position.

Confirm proper tightening of connectors.



89


Inspect hose for twist, kinks and minimum bend radius. Inspect hose/ tubefittingsObjectives: At the end of this exercise you shall be able to• check the hydraulic hose• check the hydraulic pipe• check the hydraulic pipe fittings.


90

Job sequence1 Checking hydraulic hose

• Visually check the hose for any crack.

• Keep the finger over the hose and slowly move alongthe hose and check for the kinks and twists.

• Check the bend radius according to the diameter of thehose.

2 Checking of hydraulic pipe

• Visually check the pipe for any crack or damage.

• Visually check the pipes for kinks, flat and twist.

• Check the bend radius according to the diameter of thepipe.

• Check the mouth of the pipe for burr.

3 Checking the pipe fittings

• Visually check the fitting for any damage.

• Check the pitch of the thread using screw pitch gauge.

• Check the fittings on inner edge and outer edge aremade chamfer.



91


Identify internal parts of hydraulic cylinders, pumps/ motorsObjectives: At the end of this exercise you shall be able to• dismantle the gear pump• replace the worn out component and reassemble the gear pump• test the pump for proper functioning.


92

Instructor shall give the proper instruction before dismantling of pump

Job sequence

TASK 1: Dismantle the gear pump

1 Clamp the unit in a vice from the flange side. (Fig 1)

Make sure the vice jaws are clean and havesmooth surfaces

2 Use an Allen head socket wrench to loosen the boltson the cover assembly. (Fig 2)

3 Unscrew the bolts completely and remove them. (Fig.3)

Inspect the threads for damage

4 Remove the cover assembly carefully.(Fig1)

RequirementsTools / Instruments

• Bech Vive• Allen head socket wrench• Internal snap ring plier

Equipment/ Machine

• Gear Pump - 1 No.

Material/Components

• O ring - as req.• Oil seal - as req.

Some of the pumps may have a shaft seal, insuch a case remove the cover assembly withcare to prevent any damage to the seal.

5 Place the cover assembly on the work bench. Inspectthe wear plate for wear and tear.

Remove the wear plate and seal ring from the coverassembly.(Fig 2)

Do not use sharp tools to remove the seal

6 Carefully remove the gear plate and remove the dowelpins.(Fig 3)

During disassembling the unit,mark therelative positions of the gear mesh and thebody that helps during reassembly.

7 Remove the idler shaft and drive shaft from it’s bearingbore (Fig 4 & 5).



93

Inspect the journals and the flat faces top andbottom of the gears. Ensure these surfaces arefree from burrs or scratches. If scratches arefound, clean them with very fine emery cloth.

8 Rewash the gears with light oil.

9 Remove the wear plate from the assembly. (Fig 6)

• Inspect the lower wear plate for wear, ormarks caused by overheating.

• Replace if necessary.

10 Remove the shaft seal and snap ring from the bodyassembly. (Fig 7)

Use internal snap ring pliers to remove snapring

Keep all the components of pump in propermanner and in clean place.



94

TASK 2: Replace the worn out components and reassemble the gear pump

1 Take the entire seal kit requied and compare the oldseal kit to the new one to ensure you have the correctone. (Fig 8)

Apply grease in all seals before use it

2 Prepare the body by cleaning it. Inspect the internaland mating surfaces.

Ensure the surfaces are free of burrs anscratches

3 Install the shaft seal into the body assembly.

4 Apply light lubricant in the body and shaft seal. Placethe seal in the body assembly by hand. Then, pressthe seal using a shaft seal installation tool. This willinsure the seal is in proper depth. (Fig 9)

5 Place the body assembly, with the E- ring seal groovesfacing up.(Fig 10)

6 Place the wear plate on top of the E- ring with thebronze side facing up towards the gear. The 0.25"pressure hole is to be positioned on the E-ring side ofthe body. (Fig 11)

7 Lubricate the spline end of the drive shaft with grease.Insert the drive shaft and the idler shaft in the correctbearing bore.(Fig 12)

8 Inspect gear teeth for alignment. Lubricate thecomplete gear set using clean light oil.

9 Insert the two dowel pins into the body assembly. Placethe gear plate over the dowel pins.(Fig 13)



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Make sure the gear plate is seated properly.(Fig 14)

10 Place the cover assembly on a bench with themachined surface facing up.

11 Place the rubber seal ring in the cover seal ring groove.(Fig 15)

12 Position the wear plate in the cover with the bronzeside facing up (towards gears). (Fig 16)

Pressure hole located over the circular holesin the cover.

13 Place cover assembly over the body assembly.(Fig 17).

14 Fasten assembly using torque wrench. (Fig 18)

If componants are replaced by newcomponant, run the pump in idle for some timedismantle and wash with solvent to clear offpre-setting wear particles.



96

TASK3 : Test the pump for proper functioning

Rotate the pump and check the flow rate, smoothness ofrotation and sound of pump.

Observation

1 Flow rate of pump as per specification.

2 Operation of pump should be smooth.

Conclusion:



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Construct a circuit for the control of a s/a hydraulic cylinder using a 3/2way valve (Weight loaded d/a cylinder may be used as a s/a cylinder), 4/2and 4/3 way valvesObjectives: At the end of this exercise you shall be able to• design a circuit to actuate a single acting cylinder• design a circuit to actuate double acting cylinder• design a circuit to actuate hydromotor• select the various elements as per the circuit• construct the above circuits• test the above circuits for its function, duly arresting and leakage.


98

Job sequence

Draw a circuit diagram to actuate a single acting cylinderin the given format and get the approval of instructor.

Include elements to actuate cylinder and also to monitorpressure at various points in the circuit.

Select the hydraulic elements as per the approved circuitdiagram drawn.

Mount and connect the elements on the trainer kit.

Get the approval of your instructor before switching "ON"hydraulic pump.

Switch ON the hydraulic pump.

Inspect the circuit for any leakages. (Fig 1)


• Designing, constructing and testing circuits to actuatea single acting cylinder/double acting cylinder/hydrometer.

TASK 1 : Circuit for single acting cylinder

Design, construct and test a circuit to actuate a singleacting cylinder.

TASK 2 : Circuit for double acting cylinder in 4/2valves

Design, construct and test a circuit to actuate a doubleacting cylinder using 4/2 directional control valve.

TASK 3 : Circuit for double acting cylinder in 4/3valves

Design, construct and test a circuit to actuate a doubleacting cylinder using 4/3 directional control valve.

TASK 4 : Circuit activate hydrometer

Design, construct and test a circuit to actuate a hydrom-eter using a 4/3 D.C. Valve.

TASK 1: Design, construct and test a circuit to activate a single acting cylinder.

Eliminate any leakages by (Fig 2) retightening connectorspipes.

Put off hydraulic pump, while tightening connector andpipes.

Note the position of valve and position of cylinder inthe table 1. (Table given along with circuit diagram)

Actuate the direction control valve and note the newposition of valve and cylinder.

Note it in the table 1.

Put off hydraulic pump.

Disconnect the valves and other elements and place it inrespective places.

Repeat the above sequence for task 2, 3 and 4 withrespective circuit diagram and table.


99

Production & Manufacturing Exercise 4.3.188Fitter - Hydraulics and pneumatics

Maintenance, trouble shooting and safety aspects of pneumatic and hy-draulic systems (The practical for this component may be demonstratedby video)Objectives: At the end of this exercise you shall be able to• to maintain pneumatic and hydraulic• to know about trouble shooting• follow safety on pneumatic and hydraulic.

The practical for this, component may demonstrated by video.

Instructor may arrange video’s locally and demonstate to the trainees.


100

Production & Manufacturing Exercise 4.4.189Fitter - Preventive Maintenance

Dismantle, overhauling & assemble cross slide & hand slide of lathecarriageObjectives: At the end of this exercise you shall be able to• dismantle the compound rest from the cross slide• remove out the carriage unit from the machine bed• assemble and test for functions.


101

Job sequence• Unscrew the tool posts locking handle (Fig. 1A) and

remove the tool post (1B) from the compound slide.

• Rotate the feed screw handle of the top slide (Fig. 1C)in anticlock wise direction to get it released from thedovetails of the compound slide.

• Take out the jib from the dovetail of the top slide.(Fig. 1D)

• Unscrew both the clamping nuts (Fig. 2) from theT.bolts, provided on the swivel base of the compoundslide and take out the unit.

• Remove the graduated collar (Fig. 2) of the compoundslide by removing the taper pin.

• Disengage the lead screw from the cross-slide.

• Unscrew the lock nuts from the cross-slide feed screwto remove the graduated collar.

• Take out the jib strip from the dovetails of the cross-slideso that it can be made to slide out easily.

• Unscrew and remove the saddle clamp. (Fig. 3)

• Slide way the tailstock unit and take it out of the bed.

• Slide away the saddle unit towards the right end to takeit out of the machine bed.

• Clean the parts with kerosene oil, wipe them withbanian cloth and keep the parts in tray.

• Inspect the components visually for damage and wear.

• Lubricate the parts with lubricating oil.

• Assemble the parts in the reverse sequence to com-plete the process of overhauling.

• Check the function.



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Simple repair of machinery: Making of packing gasketsObjectives: At the end of this exercise you shall be able to• mark and cut the profile and prepare gasket• fit new gasket and test the joints for leakage.


103

Job sequence• Remove the cover plate and take out the damaged

gasket.

Ensure that no portion of the gasket remains onthe surface.

• Clean the surface of the base and the cover platethoroughly.

• In the case of glue-bonded gaskets, surfaces shouldbe cleaned thoroughly using a blunt scraper.

• Smear marking medium or grease on the cover plate’sbase surface.

• Place the gasket on to the base of the cover plate andpress firmly. (Fig 1)

• Mark the geometrical shape of the gasket using a scriberor pencil. (Fig 2)

For smaller or handy objects the article can beplaced on to the gasket for marking.

• Punch out the holes using a hollow punch and ahammer or a little over- size steel ball and a hammer.(Figs 3 and 4).

• Cut out the unwanted portion of the gasket usingscissors. (Fig 5)

Cut out the centre portion first and then theexternal profile.

• Clean the corners of the studs. (Fig 6)

• Fit the gasket in position. (Fig 7)



104

• Replace the cover plate on to the gasket and tightenthe screws evenly. (Fig 8)

• Test the sealed joint for leaks and functional aspects.



105


Check washers, gasket, clutch, keys, jibs, cotter, Circlip etc and replace /repair if neededObjectives: At the end of this exercise you shall be able to• replace washer on gasket• replace clutch and keys• replace jib, cotter and circlip• replacing the above components.


107

Job Sequence

TASK 1: Replacing washer

• Remove nut using correct size spanner.

• Remove the worn out washer from the assembly.

• Place the correct size washer.

• Tight the nut with washer.

TASK 2: Replacing gasket

• Remove the damaged gasket.

• Clean the surface of the base and the cover plate.

• Place the gasket on the base plate and press firmly.

• Assemble the unit.

• Detailed assemble explained in Ex. No. 4.4.190.

TASK 3: Adjusting the clutch

_ _ _ _ _ _ _ _

_ _ _ _ _ _ _ _

• Remove the both side covers of feed gear box usingallen keys after switch off the power supply.

• Remove the terminals by using suitable spanner.

• Use a bend tubular spanner to remove the carbonbrushes.

• Remove the circlip form the spline shaft.

• Take out the clutch with spline shaft from the unit byusing M 12 bearing puller set.

• Place the assembly on work bench, clean it properly.

• If not getting proper engaging and disengaging ofclutch, dismantle the clutch unit and remove clutchplate.

• Identify the following electrical and mechanical faults.

• Check the gap with feeler gauge between clutch platesand ensure that the gap should be as mentioned by theoriginal equipment manufacturer.

• Check the spline shaft and ensure that the splines areproper.

• Assemble all the parts and once again check the uniton a work bench.

• If found satisfactory working of clutch assembly mountit in to the feed gear box of machine.

• Seated the circlip, carbon brushes and terminal.

• Fix the side covers by using allen key and check theworking of clutch assembly by switch on the machine.

TASK 4: Replacing key

_ _ _ _ _ _ _ _

• Assemble hub and shaft with parallel key.

• Assemble hub and shaft with tapered (Gib Head) key.

Parallel key fitting

• Deburr the keyways in the shaft and the Hub, clean thekeyways.

• Check the dimensions of shaft and Hub and keywaysusing precision instruments. Outside dia of shaft,inside dia of hub, length, with and depth of keyway asper the drawing (Fig 1).

• Select a length of key steel of suitable cross sectiondepending on the size of the keyway.



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• File radius at one end of the key and cut to a length plus1 mm of the keyway and file other end of the key.(Fig 2)

Ensure that the key is chamfered all around inits bottom side edges.

• Check the key width to suit the keyway in the shaft.Draw file the key, so that it is slight tap fit/light keyingfit (K7-h6) with the keyway on the shaft. (Fig 3)

• Check the key for slight tap fit with the keyway in theHub. (Fig 4)

• Apply Prussian blue on all sides and bottom protion ofthe key so that proper bearing of key on the keyway isascertained.

• Insert the key in the keyway of the shaft and tap witha light weight soft hammer. (Fig 5)

• Tap the hub on the shaft, and remove the hub from theshaft, check the key and note the high spots where thekey has made contact with the keyway of the hub.

• Lightly file the high spots away, the top of the keyshould be approximately 0.1mm clear.

• Repeat the fitting and filing operation until the hub is fiton to the shaft to the desired position. (Fig 6)

_ _ _ _ _ _ _ _



109

TASK 5: Replace/ adjust jib

• Remove the adjusting screws from the dovetail slide.

• Dismantle the gib from the cross-slide.

• Clean the slide surfaces, adjusting screws, nuts andgib thoroughly.

• Inspect all the parts for and check any damage.

• Lubricate the slideways.

• Assemble the gib.

• Tighten the adjusting screws to give the correct freedomrequired in the assembly.

• Lock the movement of the adjusting screw by thecheck- nut.

TASK 6: Replace cotter

_ _ _ _ _ _ _ _

• For removing cotter from work unit, loose the nutslightly then slowly strike with soft hammer.

• Then loose the nut completely pull the cotter pin.

• Insert the new cotter pin in the hole strike with hammer.

• After tightening the pin fix the nut.

TASK 7: Replace circlip

_ _ _ _ _ _ _ _

• Assemble external circlip using cone and compressonbush.

• Assemble internal circlip using cone and compressionpin.

• Assemble external and internal circlips using pliers.

• Dismantle external and internal circlips using pliers.

During assembly, circlip is to be spread orclosed as far as it is necessary for positioningon the shaft or installing in the housing bore.

Assemble external circlip using cone and compressorbush

• Circlips without assembly holes are best assembledby means of cones Figs (1) & (2)

• Place the cone over the shaft in which the circlip is tobe fixed.

• Place the circlip over the cone.

• Place the compressions bush over the circlip.

• Press the compression bush by suitable meansdepending upon the size of the circlip, slowly andsmoothly until the circlip is seated in the groove.

Assemble internal circlip using cone and compressionpin

• Place the cone over the bore in which circlip is to beprovided as shown in Fig 2

• Place the internal circlip in the tapered bore of thecone.

• Place the compression pin over the circlip.

• Press the compression pin slowly and smoothly untilthe circlip is seated in the groove in the bore.

Assemble and dismantle circlip using pliers

• Select suitable circlip pliers depending upon the circlipsto be used. (External or Internal)

• Remove all sharp edges from the circlip and check forthe crack, if any.

Assemble internal circlip (Fig 3)

• Hold the internal circlip (1) with help of an internal circlippiler (2).

• Press the circlip (1) with the help of the plier (2) so thatits diameter will be smaller than the hole diameter.



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• Insert the circlip in this position, in such a manner thatit will sit squarely in the groove.

• Take out the plier (2).

Assemble external circlip (Fig 4)

• Hold an external circlip (1) with the help of an externalcirclip plier (2).

• Press the external circlip plier (2) so that the circlip (2)will enlarge in diameter.

• Slide the circlip on the shaft in the enlarge position,until it is set in the shaft groove.

• Ensure that the circlip sits squarely in groove (3).

• Take out the plier.

• For dismantling the internal and external circlips theabove procedure can be reversed and applied.

Skill Sequence

Types of washersObjectives: This shall help you to• state the purpose of washers• identify the types of washers• state the uses of each type of washers.• specify the washers as per B.I.S.

Purpose

It is a common practice to provide washers under the notein bolted joints (Fig 1).

Washers help to

• Increase the frictional grip

• Prevent damage to the workpiece,and distribute forceover a larger area.

• Prevent loosening of nuts due to vibrations.

Types of washers

There are different types of washers available. They areplain or flat washers

- Taper washers

- Spring washers

- Tab washers

- Toothed lock washers.

Plain or flat washers (Figs 2 and 3)


These washers are used for bolting assemblies with fialsurfaces. The diameter,thickness and the bore diameterare proportional to the diameter of the bolt (I.S.2016)

Plain washers are available as machined or punchedwashers.


111

These are used in structural assembiles with taperedsurfaces like inside of I - Beams,channels,etc,Thesewashers help the bolt head or nut to seat square to the hole.

Spring washers (Fig 6 and 7)

Spring washers are used under nuts to prevent slackeningof the nuts due to vibrations. They are made of springsteel,and when compressed they create tension betweenthe bolt and the nut.

Tab washers (Fig 8)

These washers are used for locking the nuts.

Toothed locked washers (Figs 9,10 and 11)

These washers have serrations,cut and twisted. Whenplaced between the nut and the assembly,this washerexerts friction on both the contacting surfaces. This preventsthe nuts from slackening.


Machined washers

These washers are used for assemblies using machinecomponents. These washers are available with chamfer onone side or on both sides. They are heat treated are groundpunched washers

These do not have chamfers and are commonly used instructural fabrication work.

Tapered washers (Figs 4 and 5)


112

Specifications

The Indian Standard IS: 2016- 1967 designates a washerby name, type, size and number of the standard andmaterial.

Example

A machined washer of size 10.5 mm made of brass shallbe designated as Machined washer 10.5 IS: 2016 - Brass.

Note

For detailed specification of different types of washers,referto the following IS specifications.

Taper washer - IS: 5374 and IS: 5372

Tab washer - IS: 8068

Toothed lock washer IS: 5371

Plain washer IS: 2016

Adjust clutch pressureObjective: This shall help you to• adjust the pressure of a multi - disc clutch.


Switch off the electrical mains of the lathebefore opening the lid of the headstock.

Remove the top lid of the lathe headstock by unscrewingthe Allen had bolts. Take out the clutch lever along with thelid.

Release the index pin from the annular disc.

Rotate the annular ring to get the desired friction. If the nutis tightened too much the friction will be more and viceversa.

Insert the index pin to the annular disc hole through theadjusting nut firmly.

Replace the gasket of the top lid.

Assemble the top lid by keeping the clutch lever inposition.

Tighten the Allen screws of the lid using the Allen key.

Test the functioning of the clutch in engaging anddisengaging positions.


113

Adjust the gib stripObjective: This shall help you to• adjust and align the gib strip in a lathe.


Loosen the lock- nuts. (Fig 1)

Remove the set screws. (Fig 2)

Pull the gib out. (Fig 3)

Clean all the parts.

Check the straightness of he gib using Prussian blue.

Scrape the gib to get even surface to prevent stick- slipmotion of the coss - slide.

Lubricate all the parts.

Assemble the gib into the dovetail slide and position it.(Fig 4)

Adjust the screws and eliminate the clearance betweenthe slides for getting the correct freedom required in theassembly.

Lock the movement of the adjusting screws by th echecknut.

Hold the gib in correct position firmly while locking withcheck-nuts.

Check the function of the cross- slide.


114


Use hollow punches, extractor, drifts, various types of hammer andspanners etc for repair workObjectives: At the end of this exercise you shall be able to• select the holes for repairing• use the types of spanners• use the types of hammers• use of extractor and punches.


116

Job sequence

Instructor shall display all the tool shown in Fig1 - 10 in the section and brief their names anduses.

• Trainees will note down all the tools names and thieruses.

• Record it in Table 1.


Table 1

Sl.No Name of the tool Uses

1

2

3

4

5

6

7

8

9

10

• Get it checked by the instructor.


117


Dismantling, assembling of different types of bearing and check forfunctionalityObjectives: At the end of this exercise you shall be able to• dismount a shaft from pedestal block• mount a shaft on pedestal block• dismount ball bearing (interference fit on the shaft)• dismount ball bearing (interference fit in the housing)• mount ball bearing.

TASK 1


118

Job sequence

TASK 1: Dismatling and assembiling bush bearing

• Dismantle the cap of the block by using proper ringspanner. Hold the shaft with left hand and remove thefastening nut by right hand as shown in Fig. 1.

• Remove top shall along with cap Fig. 2a and thenremove the shaft and bottom housing as shown inFig. 2b.

• Thoroughly clean shells, cap, shaft seating (Journal)and housing bottom with kerosene by using smallbrush. Wipe out all above components with cleanbanian cloth. Do not use cotton waste to wipe outcomponent.

• Check shells and Journal for any damage, scoring marketc. Check cap, bottom housing and fastening bolt andnut for any damage and wear. Replace the damagedcomponents with new one before starts assembling.(Fig. 3). If it is not possible to replace shaft, it should bebuilt by metal deposition and machined.

• Check ovality of the bearing bore by fixing cap on thebottom housing as shown in Fig. 4.

• To remove the ovality. Remove the cap by unscrewingfastening bolts. File the bearing caps equally with flatfile to compensate for the ovality by holding the cap intothe vice as shown Fig. 5.

• Fit the two halves of the bearing back together andmake sure that, when the bolts are fitted, the load istaken by the caps and not by shells. (Fig. 6)

• Fit the shells to their housings. Check that they fitcorrectly and the oil holes align with those of thehousings as shown in Fig. 7.

• Apply marking medium around the Journal area andplace it into bottom shell for uniform contact. (Fig. 8)

• If the number of colour marking on the bottom shell ismore, it indicate shaft having proper contact withbottom shell otherwise scrape the shell to have morenumber of colour marking. (Fig. 9)



119

• Coat all the parts with the correct grade lubricant. Placethe Journal on the bottom housing, place top shell andcap on the shaft. Tighten the bolt firmly by holding theshaft. (Fig. 10).

• After mounting pedestal block clear all tools around thework spot.



120

TASK 2: Dismantling and assembiling ball bearing



121

• For ball bearings having interference fit on the shaft

Method I using press

• place the bearing with the shaft on a arbour press orhydraulic press. (Fig 1)

• For dismounting the bearing special type of puller withbracket attachment shown in (Fig. 5) is used so thatpulling force is applied on the inner ring of the bearing.

• place a ring or two parallel blocks of equal size tosupport the inner ring of the bearing. (Fig 2)

• put a dummy between the ram and the shaft

• Gently press the shaft to come out of the bearing.(Fig 2)

• Support the extracted shaft by hand to prevent damage.

• Never apply direct hammer blows on the bearing.(Fig 3)

Method II using bearing puller

• Fit the bearing pullers spindle on the centre hole of theshaft. (Fig. 4).

• Place the legs of the bearing.

• Slowly tighten the spindle of the puller by a spanner sothat the puller is ready to take the strain (Fig. 4)

• Use a keeper puller plate along with the puller whenpullers legs tend to engage with the outer ring of thebearing. (Fig. 6)

• Rotate the outer ring or the puller during dismounting ifthe pullers legs has to engage the outer ring of thebearing, when the bearing is to be used again. (Fig. 7)

• Small bearings can be removed by using a puller or witha metallic sleeve using mild hammer blows.

• To dismount small and medium size bearings, use ahammer and a sleeve a butting the lock nut or the innerring. (Fig. 8)

• Place the sleeve against inner ring if the nut is locatedinward.

• Use hammer blows for dismounting. (Fig. 9)



122

For all bearings having interference fit in the housing

• Place the wheel on two wooden blocks and fit a suitablesleeve on the face of the bearing. Apply pressure on thesleeve to drive out the bearing. This type of dismountingcan be done for a housing without any shoulder.(Fig 10)

• Similarly, for a housing with a shoulder between thebearings a soft metal drift is used to strike the bearingin different positions to drive out. (Fig. 11). A suitablepuller is also used for dismantling.

• For dismounting self aligning ball bearing, swivel theinner race as shown in Fig. 12a. Fit the legs of the pulleron the outer race and tighten the screwed spindle toextract the bearing.

• After dismounting clean the bearing with soft bristlebrush using kerosene oil or naphtha. (Fig. 12b)

• Wipe off the bearing with banian cloth.

Do not use cotton waste for cleaning or wipingoff bearings.

• Inspect visually about corrosion, damage in cage,raceways, rolling elements and outer and inner races.

• Insert the bearing around the fingers of your hand androtate gently to check that the bearing to rotatingsmoothly without any distraction and noise. (Fig. 13).

• Lubricate the bearing.

• Replace the seal, if any.

• Mounting ball bearings

• Clean and measure the shaft diameter (for shaft fit byvernier micrometer and for housing fit by vernier insidemicrometer) to check the necessary interference fit.

• Lubricate the shaft for mounting.

• Place the correct size sleeve on the inner ring of thebearing. (Fig. 14).

• Apply hammer blows using common hammer.

• Slowly drive in bearing until you get the metallic sound.

• Similar process should be adopted for the housing fit byselecting proper sleeve to sit on the outer ring. (Fig. 15)

• Use a arbour press whenever possible.



123

• The use of a arbour press or hydraulic press is particu-larly suitable, when small bearings are frequentlymounted. Lubricate the shaft and place a mountingsleeve between the bearing and press resting it on thering with interference fit. The end faces should be flat,parallel and burr free.

• Drive in the bearing into the shaft, by applying the forceby the press. (Fig. 16)



124


Perform routine check of machine and do replenish as per requirementObjectives: At the end of this exercise you shall be able to• check the machine running condition• check the oil level• check the sliding movement.


125

Job sequence

• Turn the machine off from the main power point and fityour tag, Out of order, to avoid someone can try to usethe machine during your maintenence procedure.

• Open side cover and check:

– Driving belts, if the belts are damaged, excessivecracks, or an excessive wear, they must be replaced.

– Check tension of belts.

– Check brake conditions (on models with pedelbrake).

• Turn the lathe ON and:

– Run the lathe for a couple of minutes.

– Check level of lubricant oil on vison main gear box.

– Refill if required with gear oil.

• During running test check that:

– All the automatic feeding movement are workingproperly.

– Check tail stock locking condition.

– Both lever must lock properly.

– Check top bench lubrication manual pump.

– Pull or pouch lever to verify that oil is coming to thesliding bench.

– Check level of lubricant oil of tank bench lubrication.

• Check level of coolant, refill if required:

• Lubrication, period - lubricant:

• Some point will be required to lubricate with gunoiler.

– Head stock - twice a year.

– Compound sildes, by gun oiler - daily.

– Apron & carriage- handle pump - daily.

– Tail stock nipple - by gun oiler - daily.

– Change gear nipple - by gun oiler - daily.

– Lead screw nipple - by gun oiler - daily.

– Bed ways - by gun oiler - daily.

• Coolant:

– Empty tank and fill up with new coolant every 4months.

– Avoid contact with coolant during the refillingprocess, you must wear rubber gloves.

– Test bottom of coolant tank to verify if there aresolids.

– Remove solids and try always to keep coolant tankclean.

– Run the lathe and test coolant is supplied properly.

• Electric:

– Check the main power cable for its conditions. If itis damaged, must be replaced.

– Verify conditions of all external switches.

– All switch with damage must be repair or replace it.

– Check conditions of all limit switches. They mustbe strong in position. A loose or damage limitswitch can generate a continuous fault on themachine.

• Centre point alignment:

– Once a year, depending the precision requiredwould be convenient to verify alignment of centretailsotck with centre of headstock.

– Alignment can be obtain by fitting a total parallel barbetween cantres, and the with a dial indicator verifyparalleism between centres.



126


Inspection of machine tools such as alignment, levellingObjective: At the end of this exercise you shall be able to• inspect drilling machine tool such as alignment, levelling


127

Job sequence

• Lock the table of the pillar drilling machine in mid -position.

• Level the machine using a precision spirit level and astraight edge.

• Check the flatness of the table surface and the baseplate of the machine.

• Check the run out of the internal taper of the spindleusing a dial test indicator and test mandrel.

• Check the straightness of the pillar in two differentplanes.

• Check the squareness of the table surface in twodifferent planes.

Skill sequence

Geometrical test for pillar type drilling machineObjective: This shall help you to• carry out the preventive maintenance of drill machine.

Levelling of the machine at two different positions (a) and(b) should be done before conducting the geometrical test.The permissible deviation is 0.03 per 300 mm. (Fig 1)


Check the flatness of the work table surface and the baseplate if it is machined. (Fig 2)

Check the camming of the rotating table, if the machineis provided with rotary movement. (Fig 3)

Check the run out of the spindle internal taper at twopositions.(Fig 4)

Check the straightness of the pillar and squareness of thespindle axis to the table surface (Fig 5) in two differentplanes.



Check the squareness of the table surface to the verticalmovement of the spindle housing in two planes. (Fig 6)

Check the squareness of the table surface to the verticalmovement of the spindle head of machines having anelevated spindle head. (Fig 7)

Lubricating the parts

Apply lubrication oil in main spindle, cam ofrotating table, gear box and pillar. Daily byusing a oil can with oil.


129

Inspect the following items and tick in the appropriate column and

list the remedial measures for the defective items.

Items to be checked Good working/Satisfactory Defective Remedial measures carried out

Level of the machine

Belt and its tension

Bearing sound

Exposed gears

Working in all the speeds

Working in all feeds

Lubrication system

Coolant system

Spindle & its travel

Arm & its movement

Electrical controls

Safety gaurds


130


Accuracy testing of machine tools such as geometrical parametersObjectives: At the end of this exercise you shall be able to• check the level of a centre lathe• check the true running of a lathe spindle• check the alignment of the main spindle and the tailstock spindle of a lathe• check the parallelism of the tailstock sleeve with respect to bedways.• perform practical test on turned component.


131

Job sequence• Fix the dial gauge on the carriage. (Fig 1)

• Note the dial reading at the extreme end of the quill.

• Verify the deflection of the dial reading and comparethe value with the test chart supplied. (IS: 6040)

For checking in the horizontal plane, set thedial horizontally and repeat the above proce-dure. (Fig 6)

• Project the quill of the tailstock to the maximum ex-tent possible and lock it. (Fig 2) Check the quill in thevertical and horizontal positions by a dial test indica-tor.

• Clamp the quill during each measurement. If it is notclamped it will affect the measurement.

• Place the dial plunger to contact over the free end ofthe quill in the vertical plane. (Fig 3)

Ensure that the dial is set at the topmost pointof the quill.

• Set the dial at the zero position. (Fig 4)

• Move the carriage slowly towards the entire length ofthe quill. (Fig 5)

• Fix the test mandrel into the tailstock spindle. Repeatthe same procedure to test the accuracy of the tailstockspindle bore in the vertical and horizontal positions asshown in the figure.

Checking the tail stock

• Insert a hollow test mandrel (300 to 500 mm long) inbetween the centres. (Fig 7)

Ensure that the spindle bearing is at its work-ing temperature.



132

• Fix the dial gauge on the saddle, the plunger touchinga position of the mandrel and set it to zero.(Fig 8)

• Move the carriage from one end to the other end of themandrel to check the mandrel is in correct alignmentin the horizontal position.

• Rest the dial plunger at right angles (radially) to thesurfaces to be tested.

• Set the dial plunger at the top of the mandrel andmove the saddle along the bed slowly to the entirelength of the mandrel. (Fig 9)

• Observe the reading of the dial as the saddle movesalong the beds and note for variation, if any.

The tailstock centre must be higher than thespindle centre within the permissible limit.

• Verify the deflection of the dial gauge reading and com-pare the value with the test chart. (IS: 6040)

Checking the true running of a spindle

• Locate the taper shank of the test mandrel in thespindle taper.

• Hold a dial gauge, stationary in the carriage, its plungercontacting the mandrel near its free end (Fig 10) andset it to ‘0’ position.

Rest the dial gauge plunger at right angles(radially) to the surface to be tested.

• Rotate the spindle along with the mandrel slowly byhand.

• Observe and note the reading of the dial gauge.

• Move the dial gauge near the spindle nose. Rotate thespindle along with the mandrel slowly by hand and notethe reading.

• Take readings of the dial gauge while the spindle isslowly rotated. Verify the deflection of the dial readingand compare the value with the test chart. (IS: 6040)

Skill sequence

Adjustment of the spirit level with the plane surfaceObjective: This shall help you to• adjust the spirit level with the plane surface.

Move the spirit level on the plane surface until the bubbleis in the centre of the scale.(Fig 1)

Place a straight edge against the level and clamp to theplate.(Fig 2)



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Turn the level through 180o (end for end) and place againstthe straight edge and note the displacement of the bubble.(Fig 3)

Level the lathe bedObjectives: This shall help you to• level the lathe horizontally with the help of a spirit level.

Adjust the vial to half of the total displacement of the bubble.(Fig 4)

Repeat the above sequence until the level is turned endfor end without displacement of the bubble.

Position the carriage in the middle of the bed.

Keep the spirit level on the rear slideway (i.e. the slidewayopposite the operator’s side) longitudinally at the position‘A’.(Fig 1)

Keep the second spirit level transversally at the position‘C’. (Fig 1)Take the readings of both the spirit levels.

Adjust the level of the bed till both the spirit levels showthe same readings.

Keep the spirit levels longitudinally and transversally atpositions ‘B’ and ‘D’. (Fig 2)

Adjust the bed till both the spirit levels show the samereadings.

Repeat the sequence of operation till both the spirit levelsshow the same reading in all the positions A, B, C & D.(Fig 3)



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Production & Manufacturing Exercise 4.5.197Fitter - Erection and Testing

Practicing, making various knots, correct loading of slings, correct andsafe removal of partsObjectives: At the end of this exercise you shall be able to• bind the rope ends with binding wire• tie six type of knots which is used in material handling using manila rope.


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Job sequence• Place one end of the soft copper or iron wire along the

axis of the rope by forming a loop. (Fig 1a)

• Wind the other end of the wire around the rope 10 to 15turns towards the rope end. (Fig 1b)

• Pass the end of the wire through the loop formed by thefirst end. (Fig 2)

• Pull the first end to make it tight. (Fig 3)

• Cut off the excess wire ends to make simple seizing.(Fig 4)

Binding of rope ends by wire adopting self-tighteningseizing method

• Take a soft wire and pull one end of the wire between thestrands of the rope. (Fig 1)

• Wind around the rope for 5 to 6 turns towards the ropeend. (Fig 2)

• Place the second end of the wire along the ropebetween the strands and wind around by the bights 5 to6 turns after forming a loop. (Fig 3)

• Pull the free end of the loop under the bights to make ittight (Fig 4).

• Cut off the excess wire to form self-tightening seizing.



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Binding of rope ends by wire using crowning method

• Unwind the wire strands to separate themselves to alength of 250 to 300mm. (Fig 1)

• Take strand No.1 to form a loop and pass the end inbetween the strands of the rope. (Fig 2)

• Pass strand No.2 in between the strands as shown inFig 3.

• Insert strand No.3 through the loop formed by the No.1strand and pull it tight. (Fig 4)

• Put a spike inbetween the strands to form a passage.(Fig 5)

• Spike is a tool with pointed end. It is used to poke inas shown in Fig 5 to make room for inserting rope strandend for binding.

• Insert the No.1 strand through the opening passage andpull tight. (Fig 6)

• Insert also strand No.2 in a similar way and pull tight toform crowned binding of rope end. (Fig 7)

• This method is used for fibre and cotton rope binding.



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Prepare square and reef knot for slinging

• Take two pieces of manila/cotton/polypropylene ropesof the same diameter. Pass the ends of the ropes oneabove the other and bend in the opposite direction.(Fig 1)

• Insert the bent ends one above the other in a similarway. (Fig 2)

• Pull the ends tight to get square knot Fig. 3.

• Fig. 4. Shows the reef knot.

Prepare a bowline knot with a reef knot

• Hold the A end of the rope by the left hand. (Fig 1a)

• Form a bight and a loop thereafter by the B end.

• Turn and hold end A by the right hand and end B by theleft hand. (Fig 1b)

• Pass end A of the rope through the loop formed by endB and pull it tight to form a bowline knot. (Fig 1c)

Forming clove hitch knot using rope and sheep shankknot

Clove hitch knot

• Hold the rope by both the hands in across way as shownin Fig 1a.

• Turn round the hands to form loops in the rope as shownin Fig 1b.

• Close down the loops together as shown in Fig.1c to putit around a post

• Fasten it to the post to make a clove hitch. (Fig 1d)

Sheep shank knot

• Hold the rope by both the hand and form a loop aroundone end of the rope (Fig. 2a).

• Form a reverse loop around the former loop by the topend of the rope as directed by the arrows in Fig. 2b.

• Turn the rope around as shown in Fig. 2c to proceed inthe final formation

• Turn the rope ends through the loops at the top andbottom ends as shown in Fig.2d to complete the sheepshank knot.



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FIN

4519

7Z2



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Production & Manufacturing Exercise 4.5.198Fitter - Erection and Testing

Erect simple machinesObjectives: At the end of this exercise you shall be able to• erection of lathe machine• erection of drilling machine• erection of power hacksaw machine• testing the machines after erection.


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Job sequence

TASK 1: Erection of lathe machine

• Select the space for proper functioning of machinessuch that machines normally must be convenientlyaccessible.

• Prepare the foundation plane as per the manufacturerinstruction.

• As per the plan foundation can be made.

• Insert the holding down bolt before the foundation setdown.

• According to the weight of the machine the depth of thefoundation be made.

• Machine may be placed in position for levelling andaligning.

• Before setting the foundation, a foundation bolt insertedthrough the holding down hole in the basic of themachine.

• After setting the concrette the machine is put on thefoundation bolt in floor.

• Align the machine perfectly horizontal position usingsprit level.

• The sprit level is applied to certain measuring areas,both in longitudinal and cross direction.

• Insert wedges must be driven into the gap under themachine bed.

• After inserting wedge check the level using sprit level.

• Grouting is carried out by pouring creamy mixture ofalmost pure cement.

• After setting grouting the wedges may be removed.

• The machine base is then tightly screwed to thefoundation bolts.

• After tightening the nuts, the correct position of themachine must once more be checked by means of thesprit level.

• Finally do the practical test and geometrical test.

Safety precautions

• When loading, slings should be protected from sharpedged by packing soft wood

• Before lifting ensure the load is securely slung beforetaking the lift.

• When unloading make sure that you have a firmfoundation for your stack, and make provision for theremoval of slings without disturbing the stack.

TASK 2: Erection of drilling machine

TASK 3: Erection of power hacksaw

• Follow the job of TASK 1.

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Skill sequence

Foundation planObjective: This shall help you to.• mark foundation layouts.



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Select the space for the erection of a centre lathe ma-chine.

Mark points at a distance of 1.5 m (maximum) from thepillar or wall. (Fig 1)

Draw the base line with the help of twine thread dipped inchalk powder or chalk solution. (Fig 2)

Construct the vertical base line using 3, 4, 5 method(Fig 3) as in a right angled triangle.

Mark the total base area of the machine. (Fig 4)

Draw the central line of the base horizontally. (Fig 5)

Locate the position of the holes. (Fig 6)

Mark the foundation holes for grouting. (Fig 7)



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Fix levelling bolts to the metal casing through thefoundation holes of the machine.(Fig 2)

Level the machine both in longitudinal and tranverse direc-tions using a precision spirit level of accuracy 0.02 to 0.05mm/metre.

Position the carriage in the middle of the bed.

Keep the spirit level on the rear slideway (i.e. the slidewayopposite the operator’s side) longitudinally at the position‘A’. (Fig 3)

Keep the second spirit level transversally at the position‘C’ (Fig 3)

Take the readings of both the spirit levels.

Adjust the level of the bed till both the spirit levels showthe same readings.

Keep the spirit levels longitudinally and transversally atpositions ‘B’ and ‘D’ (Fig 4)

Adjust the bed till both the spirit levels show the samereadings.

Repeat the sequence of operation till both the spirit levelsshow the same reading in all the positions A, B, C & D.(Fig 5)

Mount and level machine on anti - vibration padsObjective: This shall help you to.• level the machine on anti - vibration pads.

Lift the machine by crowbars and place wooden blocksunder the machine at all the four corners.

Select suitable anti-vibration pads depending upon theweight of the machine.

Remove the levelling bolts from the metal casting.

Mount anti-vibration pads under the machine. (Fig 1)

Lift the machine slightly by crowbars and remove thewooden blocks from the machine.



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Adjust the level of the machine as required by screwing orunscrewing the levelling bolt.

Finally check the level of the machine with a spirit level.

Lock the position of the machine by levelling lock-nutsafter completion of work. (Fig 6)

Moving machine on rollers (Drill Machine & Power Saw Machine)Objective: This shall help you to.• lift and move a drill machine and power saw machine to the desired location using rollers.

Keep a wooden block ready to be placed under base of themachine when it is lifted. (Fig 1)

Lift one corner of the machine using crowbars and place thewooden block under the machine. (Fig 2)

Lower the machine on to the wooden block.

Repeat the same procedure for the opposite corner of themachine.

Place three or four rollers evenly distributed under themachine. (Fig 3 & 4)



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Lift the machine with crowbars and remove the woodenblocks.

Lower the machine evenly on to the rollers. (Fig 3 & 4)

Check that the route is clear of obstacles before moving.

Place a roller in front of the machine.

Push the load forward slowly with the crowbars uptolocated place. (Fig 5)

As and when a roller is left behind the load, take it out andplace the same in front of the load.

Note: Fig. 6 shows the correct and incorrectmethod of handling crow bar.

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Fitter content - 4th sem-PracticalModule 1: Drill jig 4.1.159 Make a simple drilling jig 1 4.1.160...

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Transcript of Fitter content - 4th sem-PracticalModule 1: Drill jig 4.1.159 Make a simple drilling jig 1 4.1.160...